Case Study

Driving precision: How strategic master data management helped eliminate $2.8M in annual waste for a global automotive leader

The short version

Challenge:

A global automotive manufacturer struggled with inconsistent Bills of Materials across departments, causing $2.8M annual losses from expedited shipping and obsolete inventory.

Solution:

DataCatalyst implemented a centralized MDM platform using our Accelerate methodology to consolidate part data and establish automated workflows, all delivered with rapid time-to-value.

Results:

40% projected reduction in BOM errors, faster vehicle launches, and reduced scrap and inventory write-offs, which support $2M+ projected annual savings.

The challenge: Production gridlock from data chaos

A global automotive manufacturer was facing critical production inefficiencies due to inconsistent Bills of Materials (BOMs) across engineering, procurement, and assembly teams. This data disorder created misaligned part numbers and outdated supplier specifications, resulting in costly assembly line stoppages. The impact was severe – $2.8M in annual losses from expedited shipping and obsolete inventory.

The need: A single source of truth

The manufacturer identified an urgent need to resolve BOM inconsistencies through a system that could establish a single source of truth for parts data. 10-15 people were spending 15 hours weekly on manual reconciliation processes that addressed symptoms but never resolved the root cause. This situation was directly impacting production timelines, inflating costs, and delaying vehicle launches.

The approach: Comprehensive analysis and strategic implementation

DataCatalyst deployed a lean team of specialized experts using our proprietary Accelerate methodology to diagnose and resolve the core data issues:

  1. Intensive data analysis: Performed comprehensive data profiling across 20 ERPs & PLMs, and various internal systems, SharePoints, and Excel spreadsheets to quantify the scope of data challenges.
  2. Deep cross-functional discovery: Conducted targeted sessions with over 50 stakeholders across Product Development, Supply Chain, Engineering, Distribution, and Management.
  3. Process mapping: Executed Current State and Future State process-mapping workshops to document existing process flows and define the desired end state.

The solution: Precision-engineered MDM

The DataCatalyst team implemented an MDM platform that consolidated all parts data, including digital assets, CAD files, SKUs, and compliance certifications. This solution featured:

  • Advanced matching algorithms to resolve duplicate parts (such as alternator variants) and a product/variant inheritance structure to maintain future consistency
  • Role-based workflows enabling seamless collaboration between engineers, suppliers, and plant managers
  • Direct integration with ERP and PLM systems to automate material availability checks
  • A single, authoritative source of truth for all parts information with integrated ACES and PIES taxonomy

Our “SWAT team” approach and Accelerate methodology enabled rapid implementation and a significantly faster time-to-value compared to traditional consulting methodologies.

The transformation: From silos to synergy

Implementing this solution required significant operational changes. Teams accustomed to working with their own versions of parts data needed to adopt a collaborative approach using a unified platform. This transformation demanded new workflows, system training, and a fundamental shift toward data stewardship across the organization.

The results: Measurable business impact

The implementation delivered immediate and substantial returns:

  • 40% projected reduction in BOM errors, eliminating 150+ person-hours of weekly manual reconciliation
  • Faster vehicle launches through real-time supplier data synchronization
  • Reduced scrap and inventory write-offs, supporting $2M+ annual savings 

Using a minimal viable product (MVP) approach within our Accelerate methodology, DataCatalyst delivered critical business value in a fraction of the time typically required for enterprise data projects.

The future: Positioned for competitive advantage

With the MDM platform now operational, the manufacturer has fundamentally transformed its approach to product data management. The single source of truth for parts information enables more effective cross-departmental collaboration and strengthens supplier relationships.

This strategic change has positioned the company to respond more rapidly to market demands, launch new vehicle models with greater efficiency, and make data-driven decisions about supply chain and inventory management.