Project Overview
A major automotive OEM required high-volume production of ABS dashboard components. The project demanded IATF 16949 certification, PPAP approval, and consistent quality for long-term production.
Challenge
The primary challenges included:
- IATF Certification: IATF 16949 automotive quality system
- PPAP Approval: Production Part Approval Process Level 3
- High Volume: 1M+ units annual production
- Consistent Quality: Zero defects for automotive assembly line
- Long-Term Supply: 5+ year production program
Solution
Our engineering team developed a comprehensive solution:
Quality Systems
- IATF 16949 certified manufacturing processes
- PPAP Level 3 documentation package
- SPC on all critical dimensions
- Layered process audits
Production Excellence
- Dedicated production cell for automotive parts
- Automated quality inspection
- Quick mold change for production flexibility
- Packaging optimized for automotive assembly
Continuous Improvement
- Annual cost reduction initiatives
- Quality improvement projects
- Process optimization
- Customer collaboration
Results
| Metric | Target | Achieved |
|---|---|---|
| Program Duration | 3 years | 5+ years |
| On-Time Delivery | 98% | 100% |
| Quality Escapes | <50 PPM | 0 PPM |
| Total Volume | 3M units | 5M+ units |
| Cost Reduction | 10%/year | 15%/year |
Customer Testimonial
“CoreLMould has been a reliable partner for 5+ years. 100% on-time delivery, zero quality issues, and continuous cost improvement. True automotive manufacturing excellence.”
- Procurement Director, Major Automotive OEM