Initial situation:
- Major OEM customer escalated supplier due to repeated quality issues and non-conformities.
- IATF audit revealed systemic deficiencies: incomplete management reviews, ineffective problem-solving, poor KPI tracking.
- High risk of decertification and business loss; production lines faced capacity, scrap, and complaint issues.
Our approach:
- Conducted full gap analysis and redefined quality management processes aligned to IATF & VDA 6.3.
- Created and rolled out new management review framework, escalation guide, KPI dashboard, and customer satisfaction process.
- Trained management team on QMS, problem-solving, and compliance requirements.
- Implemented containment actions, root cause analysis, and CARA documentation for all audit NCs.
- Led the IATF re-audit preparation, on-site audit execution, and post-audit reporting.
Results:
- 100% closure of major IATF non-conformities and successful recertification.
- Customer escalation level downgraded; major OEM lifted high-risk supplier status.
- 30% reduction in internal scrap rates and 25% faster complaint resolution time.
- Established sustainable QMS foundation, ensuring readiness for upcoming VDA 6.3 audits.
Conclusion:
Decisive quality turnaround – securing certifications, restoring customer trust, and stabilizing operations.
