Initial situation:
- Severe quality and production issues at a key Tier-1 plant, threatening OEM line supply.
- High scrap rates, assembly defects, paint damage, and missing components led to supply disruptions.
- Lack of process control, insufficient gauging, and weak know-how transfer between plants.
Our approach:
- Deployed on-site task force to implement 100% quality control (“quality wall”) across global sites.
- Introduced daily failure tracking, Pareto analysis, and prioritized root cause elimination.
- Optimized processes: implemented bar positioning systems, thread control, and preventive maintenance.
- Improved FIFO systems, work instructions, and qualification matrices; ensured expert know-how transfer.
- Established weekly steering with OEM and supplier, with transparent KPI and action tracking.
Results:
- >90% reduction in assembly, paint, and threading defects within six months.
- Scrap rate cut by ~80%, boosting production output and cost efficiency.
- Successful VDA 6.3 audit; supplier removed from OEM Q:Help2 program.
- Phase-out of 100% inspection at OEM plants, saving inspection costs and time.
- Sustainable quality improvements through robust systems, equipment upgrades, and team training.
Conclusion:
We transformed a critical supplier from risk factor to stable partner, safeguarding OEM supply chains.
