Introduction

A high precision manufacturing supplier was supplying parts to OEM, but due to high rejections, OEM asked supplier to implement firewall inspection

Challenges

• High number of customer complaints
• No qualified inspectors at supplier end
• Remote location of supplier

Project Milestones

1. Setting up firewall inspection
2. Implementing Quality systems
3. Sustenance of systems

Implementing Quality Management systems

• Daily Work Management board
• Part wise detailed WIs for inspection
• Visual display

Training & Development

• Rigorous training program for inspectors
• Skill levels evaluation & development
• Multiskilling

Structured Problem Solving

• Q-Alerts & OPLs
• Process Audits
• 8D reports

Process Audits

• Layered Process Audits
• Catalydd Central Quality Audits

Results

1. Reduction in customer complaints by 92%
2. Improved Quality Management systems