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An international automotive supplier was faced with the challenge of ensuring the consistently high quality of its products abroad. At a plant in the Czech Republic, there were quality deviations in seat covers that exceeded the specified PPM limit. To avoid the threat of escalation and high follow-up costs, a short-term solution was needed for outgoing goods inspection directly in the customer's production line environment.
Within a few working days, an external control process had to be established that reliably detects and documents faulty parts and reports the results directly back to the production plant. The aim was to consistently adhere to the PPM values, avoid repeat errors and at the same time represent the supplier at the OEM in all quality-related issues.
After just four working days, a specialized Zettl team at the Czech plant took over the outgoing goods inspection and reworking of the seat covers directly on the production line. Defect images were recorded in detail, transmitted digitally to the plant and repeat defects were reduced by 52%. At the same time, Zettl represented the supplier at the OEM and ensured transparent, stable quality communication.
The rapid implementation of the outgoing goods inspection led to compliance with the required PPM values and prevented an escalation in supplier management. The close coordination between the plant, customer and Zettl quality team significantly increased process reliability and ensured series supply. The application achieved a significant cost reduction and was transferred to long-term quality support during the series production phase.
Response time of just 4 working days and PPM values permanently stable
Repetition errors reduced by 52% through targeted data collection
Cost reduction and sustainable quality improvement achieved at the OEM
