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Real automotive project experience — delivered with accuracy, speed, and professionalism

More than 10 years supporting Tier-1 suppliers and OEM projects across Germany and Central Europe.

Why clients choose us

• Fast reaction times (often within hours)

• Accurate documentation aligned with OEM requirements

• Clear and professional customer communication

• Strong technical background and hands-on experience

• Proven results in reducing PPM, stabilizing production and handling escalations

Trusted by leading European automotive suppliers and Tier-1 partners.

With more than a decade of hands-on experience in quality engineering and supplier support — including long-term cooperation on projects delivered to German OEMs — we provide measurable results directly on the production floor and in remote environments.

Sample Projects (Selected Projects - summarized & anonymized)

• Resident Quality Support for a Tier-1 supplier to a German OEM

Full-cycle quality management during serial production: claim analysis, containment, process audits, and corrective actions leading to stable PPM performance.

Case Study 1: Customer Escalation – Interior Plastic Component

Tier-1 Supplier → German OEM

Background

During serial production of interior plastic components, the OEM reported an increasing number of surface defects (scratches, dull spots). The supplier began losing PPM stability and an official customer escalation was approaching.

Our Role

• Provided rapid on-site support through external resident engineering.

• Performed immediate NOK part analysis from both production and the OEM line.

• Implemented containment, defined boundary samples, and aligned evaluation criteria with the customer.

• Facilitated structured 8D problem-solving and coordinated corrective v actions with production, engineering, and logistics.

Results

• 73% PPM reduction within 4 weeks

• Escalation closed before reaching the formal OEM escalation level

• Stabilized the surface-quality process and implemented new control points and operator training

Case Study 2: Root Cause Analysis & Process Stabilization – Cockpit Components

Tier-2 Supplier → Tier-1 Module Integrator

Background

A Tier-2 supplier experienced an increasing scrap rate during the assembly of cockpit components (clips, plastic and rubber parts). The NOK trend caused production disturbances at the Tier-1 plant and triggered pressure from the OEM.

Our Role

• Conducted data analysis: PPM trends, NOK categories, scrap mapping, and directional charts.

• Led 5Why and Ishikawa sessions to identify the true root causes.

• Introduced immediate containment and a structured rework process.

• Developed transparent reporting for Tier-1 and OEM, including daily and weekly KPI tracking.

Results

• 62% scrap reduction within six weeks

• Long-term corrective and preventive actions implemented in molding and assembly

• Strong improvement in communication and alignment between Tier-2 and Tier-1 quality teams

Quality Assurance for Interior & Cockpit Components

Sorting, rework coordination, boundary-sample alignment, and fast response to customer concerns during high-volume production.

Launch & Engineering Change Support

Preparation of documentation (APQP/PPAP, IMDS, control plans), SOP readiness checks, and communication with engineering teams to secure smooth implementation.

Root Cause Analysis & 8D Reporting

Structured problem-solving, Ishikawa and 5Why analysis, immediate containment, implementation of corrective and preventive measures.

Production Data Monitoring

Analysis of PPM, NOK trends, quality KPIs, and escalation reporting for suppliers delivering exterior and interior components.

Our Track Record

We have successfully supported suppliers across Europe in:

• crisis resolution & customer escalations,

• preparation for OEM audits,

• claim reduction programs,

• serial-production stability initiatives.

Delivered measurable improvements in PPM levels, escalation reduction, and audit readiness across multiple Tier-1 plants.

Our clients value fast response, accuracy, transparency, and reliable technical expertise based on real automotive experience.

Request case study

+421 915 459 315; +491 7676 699 205

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