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LEONI · Nov 2017 — Sep 2020
G2X — BMW Z4 & Toyota Supra New Project
Stood up systems for a major new automotive program from day one: positioning lines, installing and configuring all production IT.
0→1 Setup
Systems
Manufacturing
- Customers
- BMW · Toyota
- Daily production
- 300 harnesses
- Equivalent output
- ~300 cars/day
01
Problem
- G2X was a large new program (BMW Z4 and Toyota Supra) launching in the Niš plant with no existing setup to build on.
- Everything — line positioning, computers, printers, scanners — had to be installed and configured from scratch.
02
Research & Discovery
- Joined from the very first day to understand the program's layout and system requirements.
- Worked through how the new lines would integrate with the LEPS production system.
03
Solution
- Positioned lines and installed & configured the full production IT stack (computers, printers, scanners).
- Iterated day to day as the project developed and grew, keeping systems stable as scope expanded.
04
Impact & Metrics
- The project developed from an empty floor into a growing, scaled-up program.
- Reached steady-state daily production of 300 harnesses — equivalent to outfitting roughly 300 vehicles per day at full scale.
05
Trade-offs
Every project involves choices. Here I explain what I didn't do, what I chose instead, and why that was the better call for the business.
- Built for growth from the start (configurable, documented setup) rather than the quickest possible first install.
- Focused on system stability over chasing every optimization while scope was still expanding.
06
What I Learned
- Being there from day one builds the context that makes every later decision faster and better.
- 0→1 work rewards setting strong foundations: the structure you create early compounds as the program scales.