Need:

One of the world’s largest automotive manufacturers had lost confidence in the parts inventory at one of their manufacturing plants. They were in the middle of production and would fall behind if they had to close the plant. However, they needed a wall-to-wall inventory of their facilities that included two large-scale supply warehouses and a 750,000 sq. ft. assembly plant.

• The plant could not shut down to accommodate the inventory
• The inventory could not be allowed to affect the production schedule

Solution:

The automotive manufacturer’s inventory managers and RGIS worked together to plan a one-day Saturday inventory, which would allow them to maintain the existing production schedule. RGIS deployed a total of 673 management and team members across all three facilities. In one 24 hour period, the team inventoried more than 27.5 million pieces.

• RGIS would provide enough people to complete the count on time
• The plant would remain open

Results:

The manufacturer received a completed inventory file from RGIS and was able to bring up their production management system by noon on Sunday, in time to resume production as scheduled.

• All buildings completed on time
• The parts inventory could now be trusted