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An automotive supplier was obliged by the OEM to carry out inspections for several weeks following quality deviations. This measure threatened to put a massive strain on processes and delivery deadlines and was already causing costs in the mid six-figure range. Quick and structured action was required to bring the situation under control.
The aim was to create transparency about the causes of errors in the shortest possible time, coordinate communication between the supplier and OEM and lift the inspection obligation as soon as possible. All measures had to be fully documented in order to meet both technical and organizational requirements.
An experienced resident engineer was deployed directly at the OEM. Through daily coordination, structured sorting processes and digital feedback to the plant, error patterns were quickly identified and corrected. After a few days, the processes were stable again and sorting was completed. The assignment was transferred to long-term support with regular plant visits for sustainable quality assurance.
The rapid and coordinated deployment led to the lifting of the inspection obligation and a cost reduction of 95%. The consistent documentation and transparent communication strengthened trust between all parties involved. The introduction of digital defect data recording was also an important step towards sustainable quality improvement and process digitization.
Inspection obligation lifted and costs reduced by 95
Digital fault data acquisition for sustainable quality improvement
Stable processes thanks to fast, structured implementation
