Introduction

1. Post covid there was serious shortage of parts at OEM overseas location, due to backlog of 10 weeks

2. So under the pressure of production of excess qty, the parts produced at Tier-1 supplier had multiple quality issues , which was resulting in part rejections and ultimately less dispatched

Challenges

• Pressure of excess production
• Inconsistent Quality
• Excess rejection
• Dispatch issues

Project Milestones

1. Improving quality along with quantity
2.  Timely dispatches

Our Solution

Our Quality Engineers team worked closely with OEM STA team and fixed various quality issues and gaps at Tier-1 supplier :

• Conduct the Burst Run / Run @ Rate activities for 8 parts.
• Cycle time study of 8 parts.
• Capacity Calculation of suppler plant.
• Solve the Quality issues in the process.
• Conduct the PPAP – PSW (Phase 0, Phase 1, Phase 3) activities for 4 parts.
• Fixture verification and corrections for 8 parts.
• Support to Industrialization activities of machines & Fixtures.
• Support to complete the Standard LAB activities.
• Follow up for CCAR and close the open points

Results

Catalydd achieved on average 91% dispatch at sub supplier and 98% dispatch at Tier- against the monthly plans