Automotive & Mobility
Why Automotive & Mobility Must Transform Now
The automotive and mobility sector is facing rapid disruption as manufacturers struggle to keep pace with rising customer expectations, global supply chain stress, and the transition toward advanced digital and electric technologies.
Highly volatile supply chains are causing frequent delays, shortages, and production rescheduling.
Electrification, hybrid platforms, and new propulsion technologies demand new capabilities and faster innovation cycles.
Production lines face unstable cycle times, bottlenecks, and recurring quality issues.
Equipment breakdowns and inconsistent maintenance practices drive cost, downtime, and delivery risk.
Automotive companies must modernize operations, strengthen quality systems, and deploy digital technologies to remain competitive in a rapidly evolving mobility ecosystem.
BGMC’s Transformation Approach for Automotive & Mobility
Assess Operational Systems & Performance Gaps
We conduct a full assessment of your production lines, supply chain flows, equipment health, workforce capability, quality management, and logistics performance.
We identify:
Production bottlenecks and cycle-time losses
High-defect zones and process variation
Reliability and maintenance challenges
Supply chain delays, inventory issues, and logistics inefficiencies
Workforce skill gaps and compliance readiness
Outcome: A clear diagnostic of where operations lose time, quality, and cost.
Redesign for Lean, Stable, High-Throughput Operations
We redesign your manufacturing and mobility processes to ensure stability and efficiency across the end-to-end value chain.
Includes:
Line balancing, takt-time redesign, and throughput optimization
SMED, 5S, Kaizen, and Kanban system development
Standardized work and operator skill-mapping
Quality-at-the-source & error-proofing redesign (Poka-Yoke)
Inventory and material flow optimization
Outcome: Higher throughput, reduced waste, and stronger production reliability.
Deploy Predictive Tools, Automation & Digital Systems
We integrate intelligent technologies to automate decision-making, enhance planning accuracy, and strengthen operational control.
Includes:
Digital twins for automotive lines and assembly operations
Predictive quality and predictive maintenance models
IoT-based production monitoring
Real-time dashboards and plant-control towers
Automated inspection and digital traceability
Outcome: Fewer unplanned stoppages, reduced defects, and improved forecasting accuracy.
Standardize & Scale Improvements Across Plants
We establish governance, standardization, and digital-enabled playbooks to scale improvements across multiple sites, suppliers, or production units.
Includes:
Enterprise performance management structure
Cross-site benchmarking & best-practice replication
Quality, safety, and compliance standardization
ERP & MES integration for visibility across supply chain
Outcome: A consistent, efficient, high-performing operational ecosystem.
Build Capability for Long-Term Performance
We upskill teams and embed continuous improvement capabilities within your automotive and mobility operations.
Includes:
Lean & Six Sigma capability building
Safety & QHSE training aligned with global automotive standards
Leadership development for manufacturing excellence
Coaching for engineering, maintenance & quality teams
Outcome: A stronger workforce with sustained high-performance culture.
Our Automotive & Mobility Operational Offerings
Operational Excellence & Lean Transformation for Automotive & Mobility
We help automotive OEMs, suppliers, component manufacturers, and mobility service operators improve production flow, stabilize processes, reduce cycle-time variation, and achieve world-class operational discipline. Our approach eliminates bottlenecks and strengthens throughput across machining, assembly, fabrication, injection molding, and EV component production.
Services include:
Lean production system design for automotive & mobility
Value stream mapping for machining, welding, stamping & assembly
Cycle-time optimization & takt-time balancing
SMED & tooling-changeover optimization
Line balancing for multi-model production
Visual factory systems & daily performance routines
Bottleneck analysis using OEE & loss-tree methodology
Workflow standardization to reduce operator variability
Example outcomes:
Higher throughput, reduced takt-time deviation, and more predictable manufacturing performance.
Procurement Optimization for Automotive Parts, Tooling & Critical Raw Materials
We improve sourcing and material availability for automotive-grade steels, forgings, castings, plastics, electronics, fasteners, and tooling essential for stable operations.
Services include:
Supplier selection, qualification & performance monitoring
Inventory planning for components, spares & long-lead tooling
Vendor risk assessment & cost optimization initiatives
Warehouse layout for high-volume SKUs & fast-moving parts
Contract governance for Tier-1, Tier-2 & Tier-3 vendors
Example outcomes:
Fewer line stoppages due to material shortages, lower procurement costs, better vendor reliability.
Automotive Compliance Systems for Quality, Safety & Environmental Control
We implement standards required by global automotive supply chains and mobility manufacturers.
Services include:
IATF 16949 (Automotive QMS) implementation
ISO 9001, ISO 45001, ISO 14001 integration
Process control documentation & traceability systems
Internal audits & PPAP/FAI readiness
Risk-based quality frameworks & CAPA programs
Example outcomes:
Stronger compliance, improved customer audit performance, reduced non-conformances.
Quality Excellence for Zero-Defect Manufacturing & Supplier Performance
Automotive quality systems require precision, repeatability, and strict control over process variability. We strengthen quality-control and improvement programs across manufacturing and supplier networks.
Services include:
Statistical process control & capability improvement
Defect reduction & structured problem solving (8D, 5-Why, FMEA)
Incoming, in-process & final inspection systems
Gauge R&R, calibration & metrology improvement
Control plans & quality checkpoints across process stages
Supplier quality improvement for Tier-2/Tier-3 vendors
Example outcomes:
Lower defect rates, reduced warranty claims, improved OEM and customer satisfaction.
Safety & Environmental Programs for Automotive Plants, Workshops & EV Facilities
We strengthen HSE systems for stamping, welding, machining, assembly, paint booths, battery rooms, and engine test cells.
Services include:
Safety audits for press shops, welding lines & assembly floors
Chemical handling & ventilation requirements for paint shops
LOTO procedures for robotic cells & high-voltage EV systems
Noise, fumes & ergonomic hazard reduction
Environmental compliance (air emissions, waste, water)
Emergency response & fire safety programs
Example outcomes:
Fewer safety incidents, stronger compliance, safer workforce operations.
Automotive Project Management, NPI & Factory Expansion Support
We support OEMs and suppliers with complex project execution including NPI (New Product Introduction), tooling development, factory expansion, automation upgrades, and EV transition programs.
Services include:
PMO setup for automotive & EV transformation programs
Project planning, scheduling & risk mitigation
Tooling, jig & fixture development oversight
Vendor management & installation supervision
NPI readiness, line commissioning & SOP deployment
Shutdown & overhaul program management
Progress dashboards & stakeholder reporting
Example outcomes:
On-time project completion, smoother NPI launches, and stronger program governance.
Automotive Supply Chain, Logistics & Vendor Performance Optimization
We optimize supply chain processes in environments with frequent model changes, JIT/JIS delivery requirements, stringent quality expectations, and complex vendor networks.
Services include:
Supplier qualification, monitoring & rating
JIT/JIS material-flow design & sequencing
Inventory optimization for high-volume & variant-heavy lines
Inbound logistics, milk-run & consolidation strategies
Warehouse layout & storage optimization for automotive parts
Production scheduling & demand-planning improvements
Supplier risk management & dual-sourcing strategies
Example outcomes:
Fewer material shortages, reduced logistics cost, and improved supplier reliability.
Smart Manufacturing, Automation & AI for Automotive Operations
We integrate digital tools across manufacturing, logistics, quality, and aftermarket functions to improve efficiency and visibility.
Services include:
IoT for machine health, energy & equipment monitoring
Digital twins for assembly lines & EV production
AI for demand forecasting, scheduling & defect prediction
Real-time dashboards for scrap, downtime & line performance
Workflow automation for quality & maintenance
ERP/MES integration for end-to-end visibility
Example outcomes:
Higher reliability, reduced downtime, more data-driven decision-making.
Technology Stack for Automotive Excellence
Example Use Cases & Outcomes
Automotive Manufacturer Line Throughput Optimization
A global automotive producer was struggling with slow cycle times, frequent stoppages, and high changeover losses that created unstable production and delayed customer deliveries.
Challenge:Â Long cycle times, high changeover time, and inconsistent operator performance.
Solution:Â Lean redesign of the assembly line, SMED techniques, value stream optimization, and digital dashboards for real-time visibility.
Outcome:Â 17% throughput increase and 23% reduction in changeover time, improving delivery reliability.
Tier-1 Supplier — Predictive Quality & Defect Reduction
A Tier-1 supplier faced rising defect rates and customer complaints due to process variation and ineffective quality inspection routines.
Challenge:Â High defect rates, rework, and inconsistent outgoing quality.
Solution:Â SPC integration, predictive quality analytics, root-cause elimination, and automated inspection.
Outcome:Â 35% defect reduction and higher customer satisfaction.
Automotive Parts Plant — Maintenance & Uptime Improvement
A parts manufacturing facility suffered costly machine breakdowns and reactive maintenance workflows that disrupted production flow.
Challenge:Â High unplanned downtime and inefficient maintenance cycles.
Solution:Â IoT-based condition monitoring, predictive maintenance, and reliability-centered maintenance programs.
Outcome:Â 28% reduction in breakdowns and improved equipment lifespan.
Mobility Startup — ERP-Enabled Operational Integration
A mobility solutions company lacked synchronization between inventory, production, engineering, and sales operations.
Challenge:Â Fragmented data and poor operational visibility.
Solution:Â ERP integration, standardized processes, automated inventory control, and digital workflows.
Outcome:Â Faster planning cycles, reduced inventory waste, and improved coordination across teams.
Who We Serve
Industries
- Automotive OEMs (Passenger, Commercial, EV)
- Tier-1 & Tier-2 Component Manufacturers
- Mobility & Electric Vehicle Startups
- Automotive Parts, Machining & Fabrication Plants
- Engine, Transmission & Powertrain Manufacturers
- Plastics, Rubber & Interior Systems Producers
- Paint Shop, Body Shop & Assembly Operations
- Automotive Electronics & Sensor Manufacturers
- Logistics, Warehousing & Distribution Centers
Functions
- Operations & Production
- Maintenance & Reliability
- Quality & Engineering
- HSE / QHSE
- Supply Chain & Procurement
- IT, Digital & Automation
- Finance & Cost Management
- Leadership & Plant Management
Regions
Frequently Asked Questions
1. How do we start improving our automotive operations if our plant is not stable?
2. Can BGMC help us meet IATF 16949 or OEM compliance requirements?
3. Do you work with EV and new mobility companies?
4. How do you measure ROI from lean, digital, and reliability programs?
5. Can BGMC support multi-site automotive transformation?
6. Do we need advanced digital systems before starting predictive analytics?
Ready to Transform Your Manufacturing Operations?
Let’s discuss how BGMC Group can help transform your operations and drive measurable results.
Connect with our experts today to explore customized industrial and business solutions designed for your success.
We work with ambitious leaders who want to define the future, not hide from it. Together, we achieve extraordinary outcomes.