Automotive supplier
Implementation plan

Tier-2 automotive supplier · plastic injection and assembly · 2 plants · 62 presses · 260 employeesThis War Map shows how we turn an operational review into an implementation plan. The dates show a possible sequence; the scope and schedule of a real engagement are agreed with you.

Implementation plan

What changes, in which order, and who keeps each decision. 8 initiatives across 4 departments. €339-483K of illustrative annual value, with each assumption written out.

Priorities at a glance

  • 8 initiatives across 4 departments
  • €339K to €483K of illustrative annual value: capacity, freight, press hours and quality cost
  • Sample target: every premium freight booking approved with a recorded cause by the end of month 1
  • Target: the planner decides on release changes the day they arrive, instead of finding them at the dock

Automation Opportunity Map

The goal is not to add AI on top of chaos. The goal is to turn repeated fires into infrastructure: context assembled automatically, decisions routed to the right level, exceptions escalated only when human judgment is actually needed. The figures below show direct value by initiative. Broader operational value is modeled separately.

Matching and updates use deterministic rules. An agent can classify a free-text request, gather records or draft a response. Software-enforced access, validation, duplicate handling and named human approvals govern consequential actions.

The two estimates (direct value by initiative; projected annual value by operational effect) are alternative, overlapping views. Do not add them. Ranges are teaching assumptions without source measurements: volumes, time, loaded cost and error cost require validation. Investment, operation and adoption ramp remain to be deducted.

Low complexity
Med complexity
High complexity
Direct initiative value: €280-405K/yr
Supply Chain + Planning3 items
€155-225K
Premium Freight Control: approval with a recorded cause
€60-90KLow
Current state
About 6 bookings a week, approved by phone after 6 pm. The cause is recorded for 1 booking in 5, so only €18K was recharged in 12 months.
Target state
Each request opens a record. An agent gathers stock, plan, release history and transport quotes. The Plant Director approves, and above €1,500 the CEO. The cause is captured at booking. When it is a customer change inside the frozen horizon, a recharge file is prepared for Julien to send.
€60-90K/yrWeeks 2-5Low
Release Intake: EDI repair and portal capture
€30-40KMed
Current state
5 of 14 customer flows typed into Silog. Every release compared with the previous one by hand in Excel.
Target state
The two VDA flows are remapped. An agent reads portal and PDF releases and prepares the Silog import. A delta report shows each change by horizon. Sandrine validates every import during the first month; agreed rules apply after that.
€30-40K/yrWeeks 2-6Med
Release Change Triage: firm-zone alerts and replanning proposals
€65-95KMed
Current state
About 19 lines a week change inside the frozen horizon. Karim hears by phone, 1.5 days later, and rebuilds the sequence by hand.
Target state
Each firm-zone change is flagged the day it arrives, with the press, tool, insert and resin affected and a proposed sequence. Changeover kits are listed for tooling 24 hours ahead. Karim decides the plan. The customer acknowledgement is drafted with time-stamped release versions.
€65-95K/yrWeeks 5-10MedDepends on: Release Intake: EDI repair and portal capture
Quality2 items
€50-70K
8D Assistant: traceability and customer templates
€35-45KMed
Current state
D3 at 31 hours on average against 24 required. The suspect period is rebuilt from three sources, then the report is typed twice.
Target state
On a new complaint, an agent pulls MES cycles, resin lots and shipments for the suspect period and drafts the D3 in the customer's template. Thomas checks and sends it. Containment and release decisions stay with Quality.
€35-45K/yrWeeks 4-9Med
Control Plan Watch: change-to-document tasks
€15-25KLow
Current state
23 of 140 control plans behind after process changes. Updates depend on memory.
Target state
Each process change, engineering change or 8D action creates a document task. An agent lists the control plans and PFMEAs affected and drafts the changes. Isabelle approves every update.
€15-25K/yrWeeks 6-10Low
Engineering + Tooling2 items
€45-65K
Change Tracker: one record per engineering change
€25-35KMed
Current state
14 open changes followed in inboxes and folders. PPAP files take about 26 person-hours a month to assemble.
Target state
Each change has one record from drawing revision to PPAP approval. An agent checks the revision in production, collects the PPAP elements and flags what is missing. Émilie submits.
€25-35K/yrWeeks 3-9Med
Tooling Invoice Release: approval-to-invoice trigger
€20-30KLow
Current state
€410K of customer-funded tooling waiting. €22K went unbilled last year after a lost approval email.
Target state
A PPAP approval or customer tooling order triggers a draft invoice in Silog. Hélène validates and issues it. Open tooling balances are listed weekly.
€20-30K/yrWeeks 8-11LowDepends on: Change Tracker: one record per engineering change
Operations1 item
€30-45K
Press Plan Continuity: written rules and a second planner
€30-45KMed
Current state
The press plan depends on one person and one workbook. Holidays mean longer changeovers.
Target state
Tool-to-press rules, colour sequences and changeover times are written down and checked by the agent on every plan. A second planner runs the plan for two weeks before the handover is accepted.
€30-45K/yrWeeks 6-12Med

Implementation Timeline

Weeks are relative to implementation start; months represent four four-week blocks. Dependent work can be prepared in parallel with test fixtures, but production release waits for sync acceptance. This is a scenario schedule.

  1. Premium Freight Control

    Weeks 2 to 5

  2. Release Intake

    Weeks 2 to 6

  3. Change Tracker

    Weeks 3 to 9

  4. 8D Assistant

    Weeks 4 to 9

  5. Release Change Triage

    Weeks 5 to 10

  6. Control Plan Watch

    Weeks 6 to 10

  7. Press Plan Continuity

    Weeks 6 to 12

  8. Tooling Invoice Release

    Weeks 8 to 11

  9. Silog-MES link for live capacity

    Weeks 13 to 16

Month 1: Premium freight control and release intake go live. Every booking has a recorded cause. Sandrine validates every import. People review every agent output.

Month 2: Change tracker and 8D assistant in use. Release change triage starts sending firm-zone alerts to Karim. First recharge files sent by Julien.

Month 3: Control plan watch and tooling invoice release live. The second planner shadows the plan. D3 time and premium freight measured against the baseline.

Month 4: The second planner runs the plan alone for two weeks. Silog-MES link scoped. Handover accepted once the team operates and recovers each initiative without us.

Projected Annual Value

Released capacity (45.2 h/week register × 46 weeks × €50-60/h loaded cost)€104-125K
Premium freight avoided (20-30% of €372K through earlier alerts)€74-112K
Freight recharged on customer firm-zone changes (30-50% of the €152K eligible, net of €18K already recovered)€28-58K
Bottleneck press hours (18 presses × 5,500 h × 2-3% × €45/h contribution)€89-134K
Sorting and tooling (40-60% of €54K sorting, plus €22K of tooling no longer unbilled)€44-54K
€339-483K
projected annual value

Released hours go to firm-zone negotiation, root-cause work and new program launches. No headcount reduction is assumed. Press hours count only where customer demand exists for them. Recharges depend on the terms agreed with each customer. All figures are illustrative.

Phase 1
War Map
Sample deliverable
Phase 2-3
Implementation
12-16 weeks
Phase 3+
Ongoing
Usage-based

How much time could this free up?

Choose one non-overlapping task category and the people who actually perform it. These inputs are scenario assumptions; replace them with a measured baseline.

180
52,000
40
31
40

2,232

Task hours per week

€2,901,600

Annual cost allocated to this work

892.8

Potentially released hours per week

€1,160,640

Annual gross value of that capacity

Hours = people × weekly hours × task share. Allocated cost = people × annual loaded cost × task share. Potential capacity multiplies each by the releasable share.

This is not net ROI or a payroll saving. Necessary manual work remains. Adoption and quality must be measured; actual uptake may be lower. Implementation investment, model and hosting costs, maintenance and supervision are excluded. Cash savings require a separate spending decision; otherwise the benefit is capacity available for other work.

How We Work

1
War Map Review
We walk through this deliverable together. You challenge the numbers, confirm the priorities, and tell us what we missed. This is your map. We built it, but you own it.
2
Remediation
Before we build anything, we fix what needs fixing. Data quality, missing SOPs, system access. Your team gets briefed on the plan. No surprises.
3
Build + Deploy
We work directly with your operations team. Systems go live one at a time, in priority order. Release gates cover representative cases, permissions, failures and escalation; consequential actions retain the agreed human authorization. This illustrative schedule targets first production results in month 1.
4
Transfer
We train your team. We document everything. We make sure the people who run your operations can run these systems without us. The capability is yours permanently.
5
Exit
Handover is accepted when your team can operate and recover the agreed systems. Any continuing support is separately scoped, with a named owner and a documented exit.

War Map

A real engagement is scoped in the Strategy Session and may begin with a War Map or a bounded Feasibility Sprint.

Request a Strategy Session

Direct accountability. Scope agreed before work begins.