Dyson Automotive – Engineering Quality Support

Our client needed quality engineering support in the early stages of an automotive development program to instill automotive standards and best practices in a new team that had experiences widely mixed from many different industry sectors.

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Hitec Power Protection – Engineering Quality, Supplier Development and Rework Support

Our Client an Organisation in Holland was manufacturing large scale Power Generators for critical Process Back-ups for server farms of Banks and Internet Giants and other critical equipment. At the time of engagement the manufacturing and engineering process showed crucial gaps in terms of quality assurance which had a direct impact on defect occurrence in end-of line testing and field failures.

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Cosworth – Quality Control and Launch Support

At the time of engagement our client was ramping up a new CNC Machining and Assembly site with new customers for their powertrain parts. The main objective was to support the launch of the new products to get customer approvals and enable ramp up to volume.

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Mahle Powertrain – Quality Control and Launch Support

As Mahle Powertrain started to experience Quality and Out-put problems with a few of their key manufacturing lines we were asked to stabilise quality performance, reduce scrap rates and enable the higher yields to catch up on a back-log of parts which their end customers were urgently waiting for. Additionally during the time of this project a new product was launched on a new manufacturing line for which we were also asked to provide launch support until peak volumes could be reached.

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Mercedes-Benz Formula 1 – Quality Problem Solving Support

The Mercedes Formula 1 Engine Manufacturing site was experiencing quality problems with their engine parts as we were asked to support with the implementation of a robust Problem Solving Methodology bridging the gap between Engineering and manufacturing Processes.

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Audi Hungaria – Quality Problem Solving Support

The Engine team at Audi Hungaria experienced manufacturing quality problems which at the time were difficult to control. Our team was asked to support with a comprehensive SixSigma Approach to find ways of understanding the root causes and ultimately recommend permanent countermeasures.

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Hofer Powertrain

Hofer Powertrain is a niche Engineering/Manufacturer of Sportscar Transmissions that was in the middle of a transmission development project as their engineering team approached us with the request to audit their engineering program against the VDA New Product Introduction Standard. The purpose was to highlight risk in their development program early and trigger effective countermeasures to avoid quality problems at production launch stage.

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Hewland

Hewland is a small volume manufacturer of race car transmissions and approached us to perform a process audit across their entire transmission product range with a specific focus on product audits and validation testing procedures.

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IMI

The IMI team was facing a growth problem at the time we were asked to support. The order book of the operation was growing strongly but some internal processes and a lot of the supplier were not able to keep up with the growth so that Quality problems started to surface. Our team was asked to align standards with suppliers and develop them to ensure high quality and robust supply for the growth in the following months. Additionally some internal processes were also identified that we had to get on the right track.

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SMART Cars

Smart approached us just after they took over the Renualt Supply Chain after a joint-venture between the two companies was agreed. As the Renault suppliers were not aligned with the level of quality at Smart, the organization launched a significant Quality initiative to develop the top 10 of the critical suppliers to increase their quality levels over the 12 months following the joint-venture. Our team was asked to develop the worst two suppliers based on VDA 6.3 Standards used all over the Mercedes-Benz and Smart Car Supplier Network.

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Knorr-Bremse

The team at Knorr was battling through a tough Crossrail Project Phase at the time they contacted us. Knorr was manufacturing the platform screen door systems for the underground stations and where just reaching the point where production orders had to be placed at the supply base. However, at that stage not all required drawings were completed and also some validation tests were still open and the manufacturing site not ready to receive parts for the launch phase.

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Ferrari F1

In 2015 our team was approached by the Ferrari F1 team with the aim to support their internal improvement activities to increase Engineering Robustness and Development Speed.

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Sauber F1

Following Successful Projects at Ferrari F1 our team was asked to also support the Operation of the Sauber F1 team after it was joined by AlfaRomeo as part of the FIAT/Ferrari Group of companies.

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Honda F1

In 2019 our team was asked to support the Operation of the Honda F1 team as our fourth F1 client at the time.

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