Automotive - Case Studies

Plant management & Program management Product and footprint optimization Quality Supply Chain Startups and Greenfields

1. Plant management & Program management

At Elite Analytics, our consultants have successfully led full-scale plant turnarounds, guiding operations through restructuring, investment, and performance recovery. They've managed large teams and cross-functional departments in high-pressure manufacturing environments. As program directors, they've delivered complex transformation initiatives across multiple regions and business areas. This hands-on leadership ensures practical, results-driven support for supplier evaluation and development.

Plant Turnaround & Integration – United States

As Plant Manager for a major Class 8 automotive manufacturer, led the transformation of a newly acquired cab manufacturing facility:

  • Reorganized internal operations and optimized consultancy usage
  • Executed targeted investment plans across key departments
  • Directed 15 cross-functional projects across HR, Logistics, Engineering, and Quality
  • Increased production output by 115% in seven months
  • Oversaw 450 employees while cultivating a high-performance, safety-focused culture

Strategic Program Leadership – Americas

As Program Director, led industrial and cross-functional transformation programs across North and South America:

  • Headed a Project Management Office (PMO) reporting to executive leadership
  • Ensured execution of critical programs across HR, IT, and operations
  • Monitored and delivered business cases, timelines, and financial targets

2. Product and footprint optimization

At Elite Analytics, we specialize in product and footprint optimization grounded in real-world experience. Our consultants have led global initiatives to streamline vehicle portfolios, balance make-vs-buy decisions, and align manufacturing footprints with long-term strategy. From restructuring product content and reducing complexity to optimizing architecture and sourcing strategies, we've helped major OEMs enhance competitiveness and operational efficiency. Our approach blends data-driven planning with hands-on execution—delivering tailored solutions for scalable, cost-effective growth.

Large OEM. Heavy trucks. Manufacturing Footprint & Strategy Optimization – Americas

Led strategic planning initiatives for industrial footprint and vehicle architecture:

  • Evaluated make-vs-buy, proximity sourcing, and long-term site investments
  • Developed Comprehensive Vehicle Architecture (CVA) master plans
  • Supported regional supply chain and manufacturing optimization strategies

General Motors – Global Complexity Management (United States, Brazil, China, South Korea)

As Director of Analytics & Complexity Optimization:

  • Oversaw global vehicle content, pricing, and feature packaging strategies
  • Aligned product development with voice of customer, market clinics, and regulatory trends
  • Managed 75+ employees and optimized vehicle complexity to save $600M annually
  • Developed investment recommendations for $160M+ capital projects

General Motors – Portfolio Strategy & Global Program Leadership (United States & Asia)

As Manager of Global Planning & Program Management:

  • Rebuilt the GM Asia product portfolio to regain market share and brand competitiveness
  • Supported globalization of Chevrolet and Cadillac with targeted portfolio expansion
  • Led strategic resource balancing, vehicle lifecycle planning, and brand realignment
  • Drove successful program execution across multiple global regions

Ford Motor Company – Benchmarking & VAVE Optimization (United States)

As Consultant in Product Development:

  • Deployed VAVE (Value Analysis/Value Engineering) programs to achieve cost savings
  • Conducted benchmarking and teardown analysis of competitive products
  • Partnered with suppliers to identify cost-out opportunities through design and process changes
  • Delivered internal and external workshops to reduce waste across the value stream

3. Quality

At Elite Analytics, our quality expertise is rooted in leading successful transformations within complex manufacturing environments—experience we now apply directly to supplier evaluation and development. Our consultants have built and audited quality systems, reduced early failure rates, and led ISO and Lean-based improvements across global operations. This hands-on background enables us to accurately assess supplier quality maturity, identify systemic gaps, and implement targeted improvement plans. Whether evaluating risk, driving compliance, or building sustainable quality routines, we help suppliers meet—and exceed—OEM standards.

Mack Trucks - Quality Transformation – United States

Directed Quality Control and Offline Operations for a new truck platform:

  • Led a multidisciplinary team covering product audits, inspection, and offline repair
  • Achieved the lowest early customer complaint rate (FF1), lowest warranty costs, and highest audit scores across U.S. plants
  • Improved compliance and implemented robust quality systems

Volvo Group – Quality & Operations Excellence (United States)

As Manager and Consultant at Volvo/Mack Trucks:

  • Modernized quality and safety processes across production using A3, 5S, and Kaizen
  • Delivered lean coaching to cross-functional teams, mapped competence gaps, and aligned training
  • Led strategic quality improvement programs and implemented ISO 9001, 14001, and OHSAS18001 compliance
  • Managed Quality KPIs and fostered a plant-wide culture of continuous improvement

General Motors – Operational Excellence & Launch Quality (United States)

As Master Black Belt and Operational Excellence Leader:

  • Directed launch strategy to improve quality by minimizing late design changes
  • Managed high-impact Lean Six Sigma initiatives across design, operations, and finance
  • Achieved $120M in direct and $100M in indirect annual savings
  • Led strategic projects focused on business unit optimization and customer satisfaction

4. Supply Chain

At Elite Analytics, our supply chain expertise is shaped by global leadership in logistics design, supplier performance, and delivery execution. Our consultants have reengineered distribution networks, built logistics hubs across continents, and led order-to-delivery optimization for high-volume production. We bring this experience directly into supplier evaluations—assessing supply chain resilience, logistics capabilities, and operational risk. From resolving distressed supplier issues to implementing corrective actions and performance KPIs, we help suppliers stabilize operations, strengthen delivery performance, and align with OEM standards.

Global Logistics Development – Sweden, China, South Africa

Held global logistics leadership roles, shaping aftermarket and production supply chains:

  • Managed procurement and distribution for EMEA aftermarket hubs
  • Reengineered vehicle distribution networks for new plant launches in Asia
  • Designed and implemented a global logistics hub for construction equipment
  • Drove system integrations, supplier contracting, and logistics KPIs

Order-to-Delivery Optimization – United States

Directed a large-scale reengineering of logistics and order-to-delivery processes:

  • Led team responsible for delivery of 70,000 trucks annually
  • Negotiated supplier contracts and introduced new freight carriers
  • Designed operational KPIs and led IT integration with customer systems
  • Streamlined network performance and reduced delivery costs

Ford Motor Company – Global Supply Chain Risk Mitigation (United States)

As Director of Supply Chain Operations:

  • Managed crisis resolution for financially distressed and operationally challenged suppliers
  • Delivered critical supplier evaluations and implemented corrective actions to prevent plant shutdowns
  • Developed mitigation strategies protecting Ford's vehicle and powertrain manufacturing plans
  • Achieved "no lost unit" production goal by resolving complex cross-functional constraints

5. Startups and Greenfields

At Elite Analytics, we bring deep experience in launching greenfield operations and scaling startups from concept to full production. Our consultants have led new vehicle platform launches, built end-to-end supply chains, and established manufacturing systems for high-growth EV programs. This expertise allows us to support suppliers through industrialization, ramp-up, and readiness for new program demands—ensuring they meet timing, quality, and operational expectations from day one.

Greenfield Supply Chain Launch – United States

Oversaw supply chain and logistics industrialization for a new truck platform at a greenfield site:

  • Built end-to-end supply chain supporting 7,200 trucks/year
  • Managed supplier readiness, logistics planning, and warehouse setup
  • Integrated freight, forecasting, packaging, and scheduling systems
  • Delivered seamless production ramp-up

Startup Product Launch – United States

Selected for an elite, autonomous team tasked with launching a new vehicle platform:

  • Defined product scope, led feature engineering, and ensured strategic alignment
  • Directed supplier sourcing and negotiated cost-effective components
  • Led industrialization from concept through full production integration

Rivian – EV Manufacturing & Launch Leadership (United States)

As Director of Manufacturing, Quality, Operations, and Supply Chain:

  • Key leader in launching R1T, R1S, and RPV electric vehicles
  • Oversaw battery pack manufacturing, validation, and quality programs
  • Built high-volume EV assembly systems and managed ERP integration across suppliers
  • Led cross-functional resolution teams and reported progress directly to the C-suite