EV Launch Management

Our client was developing a revolutionary new EV specialized commercial vehicle and was receiving resounding positive feedback from the market. Though they had been in the segment for decades, this would be their first full vehicle launch. The client had all the technical acumen to design this sophisticated product. However, as the project neared the time to get the vehicle into production, they were experiencing some turbulence they concluded was a gap they hadn’t anticipated: the need for new model launch experience to orchestrate the people, parts, equipment, and processes for a smooth launch.

Critical Path Recovery (CPR) engaged to provide the Launch Management experience. We performed the CPR Program Rapid Assessment of the project to identify high-level vulnerabilities and tested those vulnerabilities, in depth, with the client’s data and their plan. Missing components of the project were identified, and the plan was adjusted to allow time and resources to fill the gaps. We used a trust-but-verify approach of analysis to push past the easily perceptible reality of available information to the layers beneath where issues typically reside.

CPR tracked progress and drove results with a reasonable but rigorous Launch Readiness process. We created visual management tools to track component evolution from test issue, to engineering change requests, to change status and drawing release, to purchase order, to component lead time, to material receipt, which led to the implementation of a robust change control process.

Through the process, functional needs in the organization were identified and CPR provided temporary Quality Manager, Materials Manager, Manufacturing Engineering, Process Engineering, and change control coverage to ensure continued progress on the execution of the project. Each of these roles was of a “boots-on-the-ground” nature and we were ever-present on the shop floor.

The “highlight” results CPR achieved include:

Performed virtual builds and slow builds to emphasize the handoff between product and manufacturing engineering. This enabled the team to create the value stream map, identify build issues, identify design issues, and create operator instructions.
Hired and onboarded the manufacturing Quality department.
Achieved 99.5% inventory accuracy after managing material receipt with hundreds of running changes while simultaneously implementing a new ERP system for several months.
Created a change control management tool to track engineering and purchasing, track component status, manage obsolescence, plan for rework, and track inventory movement, which enabled the team to validate the launch plan’s credibility.
Implemented visual management tools for Manufacturing Engineering to track layout, assembly aides, fixtures, and equipment while providing ME leadership to drive the team.
Created an animated simulation of the entire 2-building manufacturing process to validate cycle times, ergonomics, and manufacturing staffing needs.
Documented a credible plan for a path to launch that included a clean bill of materials, supply chain status, a timeline, and a fully populated, active issues list.
Trained the entire project team for discipline and accountability to execute the plan.

In the client’s own words, “CPR not only excels in pinpointing problems, but also stands out for their aptitude in recommending effective solutions” and CPR was at the tip-of-the-spear to implement those recommended solutions. CPR’s engagement created a map from the front office to the shop floor and helped identify vulnerabilities and implement mitigation with the result being the client’s team being left with a credible plan to bring their innovative new EV product to market.