Case Studies

A precision metal stamping supplier had failed two consecutive PPAP submissions to an OEM. The customer was threatening to re-source the business. Key issues included incomplete dimensional data, missing MSA studies, and a control plan that didn't reflect the actual production process.

Ace-Quality conducted a full gap analysis against all 18 PPAP elements, rebuilt the control plan from scratch with the production team, commissioned proper gauge R&R studies, and coached the quality engineer through the submission process.

A CNC machining operation was running 12–15% rework rates on a critical aerospace component. The root causes were unclear, operator instructions were inconsistent, and there was no standardised inspection process at each work centre.

Deployed a Value Stream Mapping workshop to identify the top three waste contributors, implemented 5S at all machining stations, created visual work instructions with in-process inspection checkpoints, and ran a one-day SPC training session for all operators.

A Tier-1 automotive manufacturer needed to qualify 8 new suppliers across 3 countries within 6 months to support a new platform launch. Their internal quality team lacked the capacity and their existing qualification process had no standardised first article process.

Ace-Quality designed a standardised FAI and PPAP qualification process, trained all 8 supplier quality contacts remotely, conducted on-site audits at 5 facilities, and managed the full submission review and approval loop with the OEM quality team.

An electronics manufacturer was experiencing intermittent solder defects on a surface-mount PCB assembly line. Defect rates fluctuated between 800 and 2,400 ppm and the team had no visibility into when the process was drifting out of control.

Implemented X-bar & R control charts for the three highest-risk solder paste parameters, trained 4 operators on out-of-control rules and reaction plans, and set up a daily reporting cadence that gave line supervisors real-time process visibility.