1.2M units delivered across 14 months. Zero line-stops recorded.

The Challenge

Modulus required a Tier-1 approved supplier to take over full production of a critical chassis mounting bracket — mid-program, with no disruption to their existing assembly line schedule. Tooling had to be qualified, first articles approved, and weekly JIT deliveries established within six weeks of contract award.
Modulus needed a top-tier supplier to jump in and handle the full production of a key chassis mounting bracket — right in the middle of the program, without messing up their assembly line schedule. They had to get the tooling approved, first articles signed off, and set up weekly just-in-time deliveries all within six weeks of signing the contract.

What We Did

Tooling Qualification

We reverse-engineered the existing tooling setup, identified two dimensional inconsistencies in the previous supplier's process, and requalified all tooling to PPAP Level 3 within four weeks — ahead of the agreed timeline.

First Article Approval

First-article samples were submitted with a full dimensional report, material certification, and process capability study. Client approval was received in under 72 hours with zero revision requests.

JIT Production & Delivery

Weekly delivery runs were established to Modulus's assembly facility — averaging 21,000 units per week across the 14-month program. On-time delivery rate held at 100% throughout.

Client

• Company: Modulus

• Industry: Automotive — Tier 1 Supply


• Location: Germany


• Relationship: Ongoing since program completion