Introduction

A Tier 1 supplier providing critical assemblies to a major UK-based OEM faced severe financial losses due to recurring welding defects. Non-conforming (NG) parts were being dispatched, leading to customer debits and reputational damage. Catalydd intervened to overhaul the welding process and ensure compliance with quality standards.

Challenges

• Dispatch of non-conforming welded parts.
• High customer debit penalties.
• Lack of standardized welding parameters.
• Inconsistent process controls.
• Insufficient training for supplier teams.

Project Milestones

1. Observation & Data Collection: On-site assessment by Catalydd’s welding specialists.
2. Root Cause Analysis: Identified variability in pre-welding processes and parameter settings.
3. Solution Design: Standardized welding parameters and created checklists.
4. Implementation: Trained supplier teams and deployed revised workflows.
5. Sustained Monitoring: Ensured adherence to new protocols post-implementation.

Our Solution

Catalydd’s welding experts conducted a comprehensive audit using international and customer-specific checklists. Key actions included:

• Process Standardization: Fixed variable parameters (e.g., temperature, pressure).
• Pre-Welding Checks: Streamlined material preparation and alignment processes.
• Post-Welding Inspections: Implemented rigorous quality checks for weld integrity.
• Training: Equipped supplier teams with updated SOPs and troubleshooting guides.
• Continuous Monitoring: Established a sustenance plan to maintain improvements.

Results

1. 76% Reduction in Customer Concerns: Drastic decline in defects and debits.
2. Defect-Wise Improvements:
   ● Net Shifting Nut Broken Projection: Reduced from 120/month to 28/month.
   ● Nut, Pin & Weld Cracks: Eliminated 95% of missing welds and cracks.
3. Part-Wise Improvements:
   ● Defects detected post-improvement dropped by 80%.
   ● Overall compliance rate increased to 98%.