What We Can Do for You
We provide hands-on Quality Engineering and Lean Six Sigma interventions designed to eliminate manufacturing waste, ensure total compliance, and drive "Right First Time" production. Whether you need rapid online statistical analysis or direct on-site shop-floor support, our services are structured to embed seamlessly into your plant operations.
PPAP & APQP Documentation Packages:
Complete compilation of Level 1–5 PPAPs, including AIAG-VDA FMEAs, Control Plans, and Process Flow Charts.
New Product Introduction (NPI) & Line Validation:
First Article Inspection (FAI) execution, Acceptance Quality Limit (AQL) sampling setup, and initial process release protocols.
ISO 9001 Auditing & Gap Analysis:
Internal QMS auditing, process compliance checks, work instruction standardization, and customer/registrar audit preparation.
Supplier Quality & Incoming Inspection:
Verification of purchased component quality, SCAR issuance for non-conformances, and incoming goods inspection protocol design.
Core Technical Tools:
APQP, AIAG-VDA PFMEA, Control Plans (CP), Process Flow Diagrams (PFD), CTQ Mapping, PPAP (Levels 1–5), First Article Inspection (FAI), Acceptance Quality Limit (AQL) Sampling Tables, ISO 9001 Clauses, Internal Audit Checklists, Work Instructions (WI / SOP), SCARs / NCR Logs
Statistical Process Control (SPC) Rollout
Minitab process capability studies , control chart setup, and line-side Out of Control Action Plans (OCAPs).
Measurement Systems Analysis (MSA & Metrology):
Variable and attribute Gage R&R studies, CMM program validation, and optical inspection equipment checks.
Multi-Variable Parameter Optimization:
Isolating complex interaction variables across machine setpoints using structured Design of Experiments (DOE).
Yield & Waste Optimization:
Cost of Poor Quality (COPQ) analysis, shop-floor scrap reduction sprints, and Lean manufacturing waste elimination.
Core Technical Tools:
Minitab Statistical Software, Process Capability, Normality Testing (Anderson-Darling), Out of Control Action Plans (OCAP), Variable Gage R&R (ANOVA & Cross-Design), Attribute Agreement Analysis (Kappa), Gage Bias & Linearity, CMM Inspection Protocols, Optical Inspection Systems, Design of Experiments (Full & Fractional Factorial DOE), Main Effects & Interaction Plots, Pareto Analysis, Cost of Poor Quality (COPQ), Value Stream Mapping (VSM).
8D Root Cause Analysis & Complaint Resolution:
Systematic investigation of customer and supplier quality escapes using 5 Whys, Fishbone (Ishikawa), and Fault Tree Analysis.
Overloaded Quality Capacity Relief:
Plug-and-play engineering support to clear backlogged engineering change notes, inspection backlogs, and open corrective actions.
First-Pass Yield & Defect Mitigation
Rapid shop-floor troubleshooting to boost first-pass yield rates and minimize rework costs during peak production.
Lean Shop-Floor Standardization:
5S workplace cell organization, visual management setup, operator job-shadowing/mentoring, and physical error-proofing (Poka-Yoke).
Core Technical Tools:
8D Problem Solving Methodology, 5 Whys Analysis, Ishikawa (Fishbone) 6M Diagram, Fault Tree Analysis (FTA), Lean Six Sigma DMAIC Framework, Kaizen Events, Poka-Yoke (Error Proofing), 5S & Visual Management Shadow Boards, Standard Work Instructions (SWI), Operator Job-Shadowing / Skills Matrices, Corrective & Preventive Action (CAPA) Verification.
DMAIC Project Execution & Facilitation:
Hands-on leadership of end-to-end Six Sigma projects (Define, Measure, Analyze, Improve, Control) targeting chronic manufacturing bottlenecks and high-cost quality escapes.
Kaizen Improvement Sprints:
Rapid 3- to 5-day targeted shop-floor events focused on cycle time reduction, workflow streamlining, and defect mitigation.
Process Standardization & Standard Work:
Transitioning improved processes into permanent standard operating procedures with visual controls to prevent shift-to-shift performance drift.
Shop-Floor Mentoring & Skill Building:
Coaching plant engineers, setters, and team leaders on DMAIC tools, root cause analysis, and practical SPC application.
Core Technical Tools:
Lean Six Sigma DMAIC Framework, Minitab Statistical Software, Process Mapping (SIPOC / VSM), Cause & Effect Matrices, Pareto Analysis, Hypothesis Testing, Design of Experiments (DOE), Kaizen Blitz Events, 5S & Visual Controls, Standard Work Instructions (SWI), Control Plans.
