A US based aftermarket company moved its manufacturing plant from US to Juarez Mexico for its power distribution lighting sockets & harness products for light vehicle and commercial trucks.
Challenge
A US based aftermarket company moved its manufacturing plant from US to Juarez Mexico for its power distribution lighting sockets & harness products for light vehicle and commercial trucks. The challenge was to re-PPAP close to 250 level 3 PPAPs for more than 20 different customers in a very short duration of 2-3 months. The company had expense and timing constraints in looking for a reliable quality partner.
Solution
Quality Software & Services
An integrated software and service solution was executed. Two onsite engineers and more than four offshore back office quality engineers were deployed to execute the PPAPs. Empower QLM quality management software was utilized to manage the workflow and approval of PPAP elements. In addition, the team helped conduct and coordinate all the plant activities including a process audit with a control plan and PFMEA for each process, and gauges & instrument calibration. SPC and MSA studies were performed by analyzing the problem, identifying the root cause for each defect, and conducting Run@Rate audits to approve PPAP packages before submitting them to end customer OEM portals
The back office quality engineers managed the complete APQP & PPAP live status updates. It provided recommendations and dimensional and statistical reports in Minitab. In addition, the team created WI and compiled the PPAP package. It executed action Items such as implementation to process optimization and standardization of quality procedure & process documents.
Benefit
Through leveraging Empower QLM technology and quality services, the company reduced its expenses and timing drastically. Empower QLM speedup the process and helped complete the project well within the company’s expectations. As part of the PPAP submission process, continuous improvement suggestions and recommendations were provided to reduce expenditures and scrap rates. The company’s end customer OEMs were happy to have their production in control.
