82%

SKUs met standard requirements

79%

SKU reduction

€1.6M

Annual cost savings

Forvia, a global leader in interiors, seating and emissions technologies manufacture, partnered with Optimas International to build a standardised global parts catalogue, resulting in faster launches, stronger supply chain performance and major commercial gains across its worldwide operations.

Situation

As Forvia continued to expand its product portfolio, the risk of SKU proliferation increased, especially across C‑Class components such as fasteners. Too many low‑cost, high‑volume parts can quickly inflate inventory, increase spend and slow down global programmes. We recognised that Forvia could unlock significant efficiency by moving to a standardised global part catalogue, improving both supply chain performance and speed to market.

Solution

Our engineering specialists partnered closely with Forvia to understand exactly how its products were assembled and how each component functioned. Working alongside key suppliers, the team delivered a comprehensive standardisation programme that included:

• Creating a global fastener catalogue for use across multiple vehicle platforms
• Identifying and removing obsolete, duplicate and non‑value‑adding parts
• Leveraging existing components to meet new engineering requirements
• Rapidly designing and sourcing custom parts through our global supplier network

This collaborative approach ensured Forvia could rely on a consistent, scalable and quality‑approved parts strategy across its worldwide footprint.

Result

By rolling out global standards across 96 plants in 20 countries, Forvia significantly strengthened its operational and commercial performance:

• Lower total cost of ownership through 79% fewer parts, improved economies of scale and reduced pre‑ and aftermarket inventory
• Reduced supply chain risk with fewer suppliers and less managed stock
• Faster product launches, supported by a quality‑approved standard parts list accessible anywhere in the world

Optimas International now deploys over 200 million global standard parts from 265 SKUs to Forvia facilities worldwide, aligned to local time zones and currencies. The success of the programme has led to Forvia expanding the initiative across additional business units, including Seating and Clean Mobility.

“Optimas International’s part standardisation programme not only reduced our piece part costs, but it also enabled us to launch new products quicker, decrease inventory obsolescence, improve product quality and increase customer satisfaction.”