A major automotive manufacturer required a highly synchronized flow of thousands of different components from over 200 distinct Tier-1 and Tier-2 suppliers to feed their assembly line. Any disruption or delay in inbound logistics would cause line stoppages, costing upwards of $10,000 per minute in lost production. The plant itself had zero space for buffer inventory.
Barry Logistics implemented a rigorous Just-In-Time (JIT) and Just-In-Sequence (JIS) methodology. We established a Vendor Managed Inventory (VMI) cross-dock facility just 5 kilometers from the assembly plant. We deployed optimized 'Milk-Run' trucking routes to collect components from regional suppliers daily. Parts were then sequenced at our VMI facility to match the exact production schedule of the assembly line and delivered at 2-hour intervals.
The automotive plant achieved true lean manufacturing, eliminating the need for 30,000 square meters of onsite component storage. Assembly line stoppages due to logistics failures were reduced to zero over a two-year period, drastically improving overall factory efficiency and capital utilization.
