Cutting PPM defects by 62% to recover OEM Tier-1 status.
OEM SLA breach was 14 days from triggering Tier-2 demotion. We rebuilt quality system from incoming inspection to final dispatch in 11 weeks.
62%
PPM defect reduction
Tier-1
OEM status retained
94%
On-time delivery achieved
11 wks
Engagement duration
The starting condition.
OEM customer threatened Tier-2 demotion within 14 days of engagement start. PPM defect rate had climbed to 1,840 against a 600 SLA. Loss of Tier-1 status would have removed 67% of revenue and forced workforce restructuring.
What we did,
in order.
- 01
Quality system audit: 4 days, complete root-cause documentation against 8D framework.
- 02
Incoming inspection rebuild with statistical sampling and supplier scorecards.
- 03
In-process quality controls deployed at six critical workstations.
- 04
Operator certification program for visual + dimensional checks.
- 05
Final dispatch inspection redesigned with poka-yoke fixtures.
What was sustained,
at month twelve.
- PPM cut from 1,840 to 690 in 11 weeks — under SLA threshold
- Tier-1 OEM status retained, contract extended for additional 24 months
- 94% on-time delivery achieved (from 78% baseline)
- Quality function reorganized with 4 internal black belts trained
- Customer audit score: A from B-minus pre-engagement
“OPEXA's team lived inside our quality function for eleven weeks. They didn't write reports — they fixed problems and trained our people to keep them fixed.”
Your operation,
your case study.
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