Introduction

A major OEM identified critical gaps in the performance of its Tier-1 and Tier-2 suppliers, with audit scores as low as 55%. With a 9-month deadline to achieve compliance (minimum 85% audit score), Catalydd stepped in to overhaul supplier systems, processes, and training protocols.

Challenges

• Underperforming Suppliers: Audit scores ranged from 55% to 72%, far below OEM’s 85% requirement.
• Tight Timeline: Suppliers needed to meet compliance within 9 months.
• Systemic Gaps: Inconsistent processes, lack of training, and poor documentation.

Project Milestones

1. Pre-Audit & Gap Analysis (July 2022): Comprehensive audits conducted across all suppliers.
2. Action Plan Design (August 2022): Customized improvement plans for each supplier.
3. Implementation & Training (August–December 2022): Process engineers worked on-site to deploy solutions and train teams.
4. Re-Audit & Sustenance (January 2023): Post-improvement audits confirmed compliance.

Our Solution

Catalydd’s structured approach included:

• Gap Identification: Detailed audits using OEM-specific criteria.
• Customized Action Plans: Targeted improvements for quality systems, documentation, and workflows.
• Hands-On Training: Supplier teams trained in SOPs, compliance, and continuous improvement.
• Sustained Monitoring: Regular follow-ups to ensure adherence to new processes.

Results

1. 100% Compliance: All suppliers achieved audit scores above 85% within 6 months.
2. Supplier-Specific Improvements:
   ● Supplier 1: Improved from 55% to 88%.
   ● Supplier 2: Improved from 62% to 91%.
   ● Supplier 3: Improved from 72% to 93%.
3. Long-Term Impact: Enhanced supplier-OEM relationships and reduced risk of penalties.