Pilot Assessment

Trammell Crow (TCC) has been the outsourced facilities management services provider for Lear Corporation’s corporate and Detroit based administrative facilities. TCC is one of the largest real estate developers and facility management service providers with revenues of approximately $1.3B. Lear is a $19B first tier automotive supplier of seats and interior systems. They have 295 manufacturing facilities worldwide. 40% of their manufacturing facilities are domestic to the United States with the remainder of their production performed abroad. TCC has been working to expand its FM services in the manufacturing environment. In an attempt to define the potential savings within the manufacturing portfolio, TCC commission us to perform an assessment of 15 manufacturing facilities within the US.

This assessment was to quantify the savings that are available in the plants outside the core manufacturing operations. The Assessment and analysis took 8 weeks and involved the budget review of 15 plant and onsite visits to 11 facilities. The team included 18 members ranging from analysts to field engineers and project managers.

The pilot uncovered approximately $5M in operational savings requiring just over $6.2M in capital and expense funding. This generated a simple payback of 1.2 years. These savings were generated from 134 discrete projects in 7 service categories. The extrapolation of this initiative indicated approximately $120M in savings potential with investment requirements of $150M. The project planning revealed that the entire initiative could be complete within 36 months. TCC has included the results of the pilot program in its account management plans and now has global responsibility for all the Lear’s facilities.

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