Porsche Cars North America, Inc. is based in Atlanta, GA, is the exclusive U.S. importer of Porsche sports cars. Established in 1984, it is a wholly-owned subsidiary of Porsche AG, which is headquartered in Stuttgart, Germany, and employs approximately 400 people who provide parts, service, marketing and training for 200+ dealers. Porsche’s high-performance sports cars, SUVs and sedans includes the 911, Boxster, Cayman, Panamera, Cayenne, Macan, and the 918.

The Challenge

With over 47,000 cars sold in 2014, Porsche finished the year up 22 percent over the previous year. Each new Porsche arriving at a U.S. port receives a new vehicle wallet containing manuals and up to eight additional communication pieces; each car model specific. Porsche was not satisfied with the current vendor’s turn time or wallet accuracy and felt it needed to make a change. As the vessel arrives at the port, the wallets are matched to the specific incoming vehicles. Once the vehicle is inspected and all the documentation is completed it is then delivered to the dealer. Porsche was facing costly scheduling and production delays of the wallets. Additionally, wallets were not being kitted correctly, inventory of the contents was mismanaged, and finally, the wallets were being sent to the incorrect United States and Canadian port authority.

The Solution

All Points conducted a thorough business review of the existing process that included what and what was not currently working. As part of the process, the All Points implementation team visited and met with the Porsche port authority team in Brunswick, Georgia. All Points analyzed the process from start to finish. The analysis started from the actual wallet contents ranging from production method, scheduling, inventory management, how content updates/edits are communicated, to scheduling the vehicle wallets to arrive at the port at the optimal time. Other notable aspects of the program improvement included how communication was deciphered from Porsche’s supplier base, the origination of the vessel file, and the Porsche support center team. On a regular basis, business reviews were conducted to discuss current business conditions and emphasize continuous improvement in the workflow.

The Results

Porsche saw a significant improvement in the delivery of their vehicle wallets to the ports. Additionally, the overall program cost was decreased by 27% as a direct result of improving the management of the production, kitting, and shipping of the wallets. Major cost savings were realized in reducing inventory levels, freight, improved quality control, and internal labor overhead. Also, the time from when the vessel file was issued to the arrival date was nearly cut in half. Porsche was overjoyed with the program results and pleased with the added time they could focus their efforts on producing and selling world class vehicles.