Cutting Lead Time 38% for a Tier-1 Automotive Bracket Program
A Tier-1 automotive supplier needed a second source for a structural bracket family with an aggressive ramp schedule. Here's how the program went from quote to full-rate production.
The challenge
A Tier-1 automotive component supplier needed a qualified second source for a family of structural brackets, with a ramp schedule that left little room for a slow first-article process. Their existing supplier's lead times were putting a vehicle program launch date at risk.
What we did
Our tool room built dedicated fixturing in parallel with the customer's PPAP documentation review, rather than waiting for sign-off to start. First articles were machined, measured on our CMM, and submitted within three weeks of drawing receipt.
38%
Lead time reduction vs. incumbent
0
PPAP rejections on submission
6 weeks
Quote to full-rate production
“We needed a second source that could move at the speed of our launch schedule, not the speed of a typical qualification cycle. That's exactly what we got.”
— Program Manager, Tier-1 Automotive Supplier
Result
The program is now in full-rate production across two bracket variants, with the customer's engineering team citing the parallel tooling and qualification approach as the main driver of the timeline recovery.
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