Case Studies

Outcomes, with the numbers attached.

Four engagements across automotive and appliance manufacturing in Gujarat — what was broken, what changed, and what it was worth.

Automotive machining · 140 employees

Ahmedabad Tier-2 supplier: IATF 16949 in 8 months

Challenge: A repeat OEM order was blocked pending IATF 16949 certification. Warranty claims were running high and two customer audits had already returned major non-conformities.
Solution: Full gap analysis, process re-mapping with turtle diagrams, Core Tools training for 18 engineers, control-plan rebuild on the top six part families, and two internal audit cycles before the stage 2 assessment.
Outcome: Certified with zero majors, a ₹2.5 Cr OEM contract signed, and warranty claims down 35% year on year.
Timeline: 8 months

“The audit was the easy part by the time we got there. The line changes did the work.”
Operations Head

Appliance component assembly · 60 employees

Challenge: Scrap and rework were absorbing margin, but nobody could say how much. Costs were spread across three spreadsheets and never reconciled to finance.
Solution: Built a COPQ baseline reconciled with the P&L, ran loss-tree analysis, and executed 8D projects on the top three drivers — press-shop rework, incoming component variation and sorting labour.
Outcome: COPQ down from 4.1% to 2.4% of turnover, roughly ₹38 lakh recovered annually.
Timeline: 5 months

“For the first time we argue about quality using rupees, not opinions.”
Managing Director

Precision machining · Micro enterprise

Challenge: The owner wanted export credibility but had stalled twice on ZED paperwork and was unsure which subsidy rate applied.
Solution: Eligibility mapping, Udyam and ZED portal filing, Bronze evidence pack, parameter-by-parameter gap closure to Gold, and full handholding-grant claim support.
Outcome: ZED Gold achieved, 80% of certification cost subsidised, and a ₹4.2 lakh grant used for in-house testing equipment.
Timeline: 7 months

“The grant paid for the measuring lab we had postponed for three years.”
Proprietor

Wiring harness · Tier-2 automotive

Challenge: Customer line rejections triggered a controlled-shipping level 1 and threatened the supply agreement.
Solution: Weekly pre-dispatch third-party inspection, defect classification retraining, poka-yoke at two crimping stations, and a documented containment exit plan.
Outcome: Line rejections down 62% in one quarter, controlled shipping exited, and the supply agreement renewed.
Timeline: 3 months

“Independent inspection gave our customer the confidence we could not buy with promises.”
Quality Manager

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