Real solutions. Proven results.
Global Power Leader +VMI and sequence transition into Industrial manufacturing plant
The Challenge
Phoenix Assembly was asked to reorganize, consolidate and increase efficiencies for 85 unique part numbers. The customer operation had several planners, numerous suppliers in oversees locations, bloated in-plant and warehouse on-hand inventory, creating cash flow constraints, and part fallout due to quality issues.
Our Solution
We identified many inefficiencies and waste within material handling and cross-dock operations due to having both an in-plant and off-site inventory warehouse. We eliminated all cross-dock costs by consolidating into one facility. This consolidation also reduced overhead significantly. We controlled future inventories by operating a system of just in time with the supplier base, no longer having excess inventory that exceeded 60 days on hand. This direct-action improved cash flow instantly.
The Results
Identifying inefficiencies was the key to success for this customer. Too much of the same thing crippled their operation and their part quality suffered. No longer. Phoenix Assembly turned the operation around, greatly improving part quality and improved “right first time” percentage. Inventory is now managed and audited regularly, the supplier base is reacting timely, and the single facility is lean and efficient.
Large Automative Supplier +Supply chain take-over, subassembly design and lot control development
The Challenge
The project involved a complex subassembly containing components critical to EPA emissions compliance and overall engine performance. Key components were sourced from two non-U.S. suppliers, creating added complexity around traceability and quality control. To support regulatory and performance requirements, the customer needed full lot-level traceability of new components tied directly to each engine serial number (ESN), while ensuring that any issues could be isolated quickly without disrupting production.
Our Solution
Phoenix Assembly was engaged to design a traceability solution and reengineer the subassembly process to meet these requirements. A new assembly workflow was implemented using one-piece material flow, integrated fail-safes, full lot control, and complete product serialization across all components. Phoenix collaborated with Tier II suppliers to modify inbound barcodes to include lot data and developed proprietary software to scan barcodes, assign unique serial numbers to each component and returnable container, and link all manufacturing and lot information directly to the job order. The system was fully integrated into the customer’s production line, requiring each subassembly to be scanned prior to installation, with all data tied back to the ESN for end-to-end traceability.
The Results
The solution enabled full lot-level tracking for all overseas-sourced components, providing complete visibility and control across the supply chain. Serialization of both parts and containers allowed for rapid, targeted containment as design issues were addressed, avoiding unnecessary disruption. The integrated lot control and scanning process ensured that design changes could be tracked seamlessly at the production line. As a result, all parties were able to stay ahead of design changes and prevent large-scale containment events, protecting compliance, performance, and production continuity.
Tier-1 Automotive Supplier +Supply chain take-over, subassembly design, fail-safe development, PPAP, packaging, and daily plant delivery
The Challenge
The customer was receiving a complex subassembly from another division within its organization, but the program was challenged by poor supplier communication around lead times and annual volume requirements. Critical subassembly fail-safes were not in place, contributing to a 33% quality fallout during engine testing and creating downstream disruptions. These quality issues, combined with inconsistent coordination, led to on-time delivery problems that affected production schedules. Compounding the issue, ineffective management of returnable packaging caused shortages at line side, resulting in additional material handling and production downtime.
Our Solution
Phoenix Assembly was engaged to quote and then design a new subassembly process to address the program’s quality, delivery, and coordination challenges. The team engineered a redesigned assembly flow incorporating one-piece material flow, fail-safes, lot control, and full product serialization across all parts. We assumed end-to-end ownership of the supply chain, including supplier setup, EDI, purchasing, inventory, freight, customs, and trade compliance, while serving as Tier I for all supplier defects and managing quality and delivery performance across Tier II suppliers through a structured seven-step quality process. As a result, Phoenix Assembly was awarded seven additional products of similar design across three customer locations.
The Results
The redesigned program reduced overall defect levels to below 35 PPM while supporting annual production volumes of approximately 400,000 parts. Delivery performance improved to 100% on-time delivery for two consecutive years, restoring reliability across the supply chain. The customer also achieved increased throughput during engine testing as quality and process stability improved. In addition, rework costs were reduced by approximately $500,000 per year, excluding additional repair expenses and other indirect costs tied to defects or late deliveries.
