We were approached by a leading automotive manufacturer facing a recurring quality issue with the leather material used in the production of their vehicle seats. The defect was impacting the final appearance and durability of the product, putting their production timelines and customer satisfaction at risk. Our team investigated the root cause through detailed on-site analysis and traced the issue to an inconsistency in the leather from their vendor. We helped implement containment actions at the plant while working directly with the supplier to correct the issue at the source.
The Challenge:
The client, a prominent manufacturer, was grappling with a critical challenge: an alarmingly high rate of product defects. This issue wasn’t isolated to the final assembly line; its roots extended deep into their supply chain, primarily manifesting as significant quality control problems with incoming raw materials. This systemic breakdown in quality assurance at the initial stages was directly contributing to the unacceptable defect rates in their finished goods, leading to increased waste, rework, and ultimately, damage to their brand reputation and profitability.
The Solution:
GGS performed a detailed root cause analysis and implemented containment at the client’s plant while working directly with the material supplier to correct the inconsistency.A meticulous root cause analysis was conducted by GGS, pinpointing the precise origins of the issue. Simultaneously, containment measures were swiftly implemented at the client’s manufacturing facility to prevent further disruption. In a collaborative effort, GGS partnered directly with the material supplier, engaging in a thorough investigation to rectify the inconsistency at its source, ensuring a comprehensive and lasting resolution.
Primary Improvement:
Reduced defect rate.
Significance:
The client was able to resume normal production, protect their brand reputation, and strengthen their quality standards.