EMUSKI enabled product cost optimization for a European automotive facelift program
Who the Client Was
A leading German automotive manufacturer planning the launch of a new facelift model for the Indian market. They faced tight production budgets and needed innovative strategies to reduce costs without compromising quality.
The Challenge
The client needed a structured approach to generate actionable cost optimization ideas for multiple vehicle components and manufacturing processes:
- Ensuring production cost reductions for the India facelift model
- Maintaining global quality and regulatory standards
- Generating enough implementable ideas to prioritize high-impact initiatives
- Avoiding delays or costly trial-and-error experiments
Traditional approaches produced only a handful of suggestions, which wasn't enough. The client needed fast, creative, and practical POC ideas.
How EMUSKI Helped
EMUSKI designed a 3-day workshop sprint to deliver immediate results:
Day 1 – Discovery & Analysis
- Reviewed production processes, supplier contracts, material usage, and energy consumption
- Identified high-cost areas and potential opportunities for savings
Day 2 – Collaborative Ideation
- Conducted intensive brainstorming sessions with cross-functional teams
- Focused on practical, high-impact cost-saving ideas tailored to the India facelift project
Day 3 – Feasibility, Prioritization & Roadmap
- Screened ideas based on potential impact, ease of implementation, and ROI
- Delivered 70 actionable POC ideas, including:
- Material optimization and waste reduction
- Energy and utility efficiency
- Supplier benchmarking and consolidation
- Production workflow improvements
- Automation and process streamlining
Outcome
- 70 Ready-to-Test POCs: A large pool of ideas ready for pilot implementation
- Rapid Prioritization: Client could identify high-impact cost optimization strategies quickly
- Accelerated Decision-Making: Workshop enabled fast alignment across teams
- Foundation for Long Term Savings: Many POCs had the potential to scale into significant cost reductions
Client Feedback
"In just three days, we went from uncertainty to a portfolio of 70 actionable POC ideas. Their structured and hands-on approach gave us clarity and confidence to implement cost-saving measures for our India facelift project"
