Case Studies

Magneti Marelli

General Description

  • Magneti Marelli, a Global Tier I Automotive Supplier of lighting and exhausts, was launching the Clarkston Automotive facility for the new Dodge Ram and initially engaged TPT to provide WPI support
  • Support general launch activities in layouts, process flow and timing
  • In addition, TPT was asked to support and make suggestions for optimization and error proofing for all areas including assembly, pre-production and logistics


  • Develop and track all required actions on a master planning document with timing
  • Open issues tracking and coordination of issue resolution
  • Workstation deliverables documentation and tracking including workstation CAD drawings with all elements in each station
  • Support each pillar lead in understanding requirements, creating and tracking of WPI documents
  • Facilitate workshops and meetings among pillars to coordinate change management of EBOM, facilities, equipment and logistics
  • Identify and coordinate the creation of stands SOPs for critical processes


  • Station review workshops have identified several errors on EBOM descriptions, parts in wrong stations and missing data
  • Trained over 20 people on WPI process
  • Next steps are to optimize all key areas including assembly line

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