Stabilising Quality Performance for Supplier to a major OEM
The Challenge
A major automotive interiors manufacturer with approximately 450 employees in an affected plant in the Czech Republic, faced significant operational challenges during the launch of a new project for a customer, a major OEM in Hungary. The plant entered a Level 2 escalation, indicating serious quality concerns requiring immediate corrective action. The situation was compounded by wide-spread dissatisfaction with their existing sorting provider.
With 95% of outbound shipments requiring rework, the supplier risked missed delivery deadlines, increased operational costs, and potential disruption to their customers production line. Failure to resolve these issues swiftly could have resulted in line stoppages, financial penalties, and the possibility of NBH (New Business Hold).
Recommended directly by the Tier-1 supplier’s OEM customer for our processes and system standards, the key stakeholders turned to G&P to stabilise the situation.
The Solution
G&P deployed a professional and highly skilled, Czech‑speaking team, with technical expertise and with a focus on NOK part analysis. G&P deployed full on-site support, including a dedicated plant task force coordinator,
supported by three team leaders and twenty‑two inspectors. At its peak, the project operated with 25 personnel per day, ensuring rapid and sustained control of the escalation, through consistent inspection, end of line checks, packaging cleaning, rework, and hands on problem solving. G&P fostered a partnership approach, creating clear communication between the G&P OEM & Supplier plant operation, the OEM and the Supplier, with transparent reporting of data.
G&P delivered a comprehensive service package including inspection, end-of-line verification, packaging cleaning, rework, and detailed problem analysis. As part of this service package, every part checked was photographed, including its bar code label, which would provide the supplier with data and trends on any non-conforming parts. This helped both parties put countermeasures in place to prevent recurrence. Working closely with the supplier’s team, we ensured all improvements were introduced smoothly maintaining stability, confidence, and a strong sense of partnership throughout. Beyond operational execution, the team proactively recommended process improvements, optimised parts handling, and advised that more suitable packaging solutions were required to reduce defects.
The Results
G&P's intervention delivered immediate, measurable, and highly visible improvements. The quality issues impacting the OEM were stabilised to the extent that the OEM’s quality wall was fully eliminated, and the supplier’s escalation level was reduced from Level 2 to Level 1.
With the data our team gathered on NOK parts, the supplier was made aware of packaging and design issues that was causing complications at the OEM plant. These invaluable insights presented both the supplier and the OEM the opportunity to agree necessary improvements.
The collaboration and communication between G&P containment in the OEM plant and the local quality wall was key in achieving a quick trend turnover. OEM auditors also confirmed a significant improvement in the suppliers standing and reputation following G&P’s involvement.
G&P has since taken full responsibility for all internal quality wall operations at the supplier’s plant and continues to support containment and rework activities. Further collaboration is already progressing, with quality wall negotiations underway at another plant.