Stallion, a leading tier 1 supplier for the automotive industry, partnered with Auk Industries to unlock real-time visibility, uncover hidden capacity, and drive measurable productivity gains.
Before this collaboration, manual reports showed 90 % + machine utilization—creating pressure to invest in new machines. Auk’s Digital Operational Excellence Platform (I4.0) uncovered the truth: the plant’s actual OEE was only 41 %, revealing substantial untapped capacity and avoiding unnecessary CAPEX.
⚙️ PHASE 1 — BUILDING THE FOUNDATION
Key Achievements
✅ 100% real-time shopfloor visibility
✅ Improved operator discipline on start/stop times
✅ CAPEX avoidance: management cancelled the purchase of 8 machines after seeing under-utilization via Auk’s Utilization Heatmap
✅ True OEE: 41%, verified by ML-based auto-cycle-time analysis across hundreds of SKUs
✅ Top 3 losses: material waiting, WIP prep, operator idle (≈15–20% downtime)
✅ 15% manpower reduction with no throughput loss
🚀 PHASE 2 — OPERATIONAL EXCELLENCE PROGRAM (OEP)
After establishing a solid data foundation, Stallion and Auk Industries launched the Operational Excellence Program (OEP) to drive process stability and continuous improvement.
The program focused on strengthening SIOP (Sales, Inventory & Operations Planning) and executing Value Stream Planning initiatives across key product lines.
Auk’s team conducted Lean Masterclasses and hands-on training sessions, guiding the Stallion team through every stage of the improvement cycle:
- Drawing and analyzing Value Stream Maps (VSMs)
- Identifying current bottlenecks and root causes
- Developing actionable improvement plans
- Executing solutions with both on-site and remote guidance
Auk also supported Stallion in refining production planning and recognized participants who successfully completed the program through official certification.
OEP Results
- First (Pilot) Product – Labour Productivity Improvement
- Output increased from 1,000 pcs/shift to 1,350 pcs/shift (+35% productivity)
- Achieved within 2–3 months through Auk’s structured coaching and hybrid (offline + remote) support
- Second Product – One-Piece Flow Implementation
- OEE improved from 50% to 78–80% daily
- Production time reduced from 8 hours to 4.5 hours (~40% improvement)
- Achieved within 1.5 months
- Third Product (Ongoing) – Value Stream Redesign
- Machines and operators reduced from 4 to 3, improving utilization and efficiency (~25% improvement)
Through these initiatives, Stallion achieved an additional 10% manpower reduction, bringing the total manpower optimization to 25% while maintaining or increasing production output.
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“Auk Industries’ Digital Operational Excellence Platform helped us uncover our true production capacity, eliminate waste, and empower our teams to work smarter – not harder.”
— Operations Director, Stallion Manufacturing
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Next Steps
Auk Industries and Stallion are now implementing a Kanban system to streamline upstream material flow and further strengthen production stability and inventory control.
Key Takeaways
✅ Full visibility across legacy + new machines
✅ 35–40 % productivity improvement
✅ 25 % manpower optimization
✅ Avoided major CAPEX investment
✅ Sustained Lean culture through data-driven OEP
