Case Studies


General Description

  • Faurecia, a Tier One Automotive Supplier, was experiencing significant productivity issues and quality defects which resulted in large amounts of downtime and re-work to the plant and the customer
  • TPT provided industrial engineers to the seat assembly plant in Tuscaloosa, Alabama for the implementation of productivity improvement initiatives utilizing Lean Methodologies for the removal of waste and inefficiencies out of their operations.


  • Conducted time studies to develop a baseline for process optimization activities and manpower reduction plan
  • Development of current state standardized work sheets and Yamazumi charts for analysis and the reduction of waste
  • Conducted root cause analysis activities with the plant staff to ensure the sustainability of the transformation process
  • Developed and supported a training program for the installation of the optimized processes for future state
  • Supported the implementation of the new optimized processes and layouts


Over $750,000 in documented cost savings with the reduction of 18 FTEs through line balancing activities, waste removal and process optimization

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