Case Study
rebuild trust
Fewer rejections
The challenge
An automotive manufacturing partner supplying critical engine components to major OEMs across North America and Asia saw a rise in external customer rejections through 2024. By year end, 40 incidents had triggered controlled shipping status and a costly third-party inspection requirement, straining key OEM relationships. The root cause wasn’t effort, it was a lack of standardization and consistency in the inspection process.
The solution
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Upgraded the inspection workforce with better pay and dedicated on-site leadership
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Turned existing spec sheets into a documented, repeatable inspection workflow
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Built structured onboarding, certification, and hands-on mentorship for every inspector
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Introduced boundary samples to remove subjectivity from accept/reject decisions
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Combined inspection and packaging into one continuous process to reduce handling risk
Results
75% Fewer customer rejections
3 Months
Consecutive zero defects
Removed
from controlled shipping status
When standards are challenged, the answer isn’t more oversight, it’s a better system.