Quality problems in series production rarely start in series production. They start months earlier, in an incomplete risk analysis, a process that was never validated or a launch that went ahead too soon, and fixing them later costs far more. Our APQP and PPAP support helps suppliers and their customers plan quality from the start, prepare product and process approval, and take new products from development to stable series production.

Most quality problems in series production are created much earlier: in incomplete risk analysis, in processes that were not validated under real conditions, or in launches that started before the supplier was ready. Correcting them once production is running is always more expensive and puts customer programs at risk.

Automotive customers therefore expect a structured approach to product and process development, clear evidence at each program milestone and a controlled transition to production. Many organizations have the technical knowledge to do this, but not always the resources or experience to manage it consistently across several programs at the same time.

Our services follow the path of a new product through the supply chain: from the supplier and its processes, to production, launch and series production. At each stage, we help our customers confirm that the product, the process and the supplier are ready to move to the next step.

We can support a single program milestone, such as a PPAP submission or an industrialization audit, or accompany a program from quality planning through to stable series production. We work with the supplier’s teams and report objectively to the customer, so that risks are visible early and actions are taken in time.

Advanced Product Quality Planning (APQP) gives structure to product and process development, while the Production Part Approval Process (PPAP) demonstrates that the supplier’s process can consistently produce parts that meet all requirements. We support suppliers and customers through both.

Our support covers quality planning, the definition and follow-up of program milestones, supplier readiness reviews and the review of documentation and evidence at each phase. Before submission, we assess PPAP readiness, identify gaps and open issues, and follow up corrective actions until the submission is complete. We also work with equivalent VDA-based approaches, such as maturity level assurance and production process and product approval, when these are the customer’s requirements.

The Automotive Core Tools are the methods that turn quality requirements into daily engineering and production practice. Applied well, they reduce risk before it reaches the customer; applied only on paper, they create documentation without effect.

We support organizations in the practical application of Failure Mode and Effects Analysis (FMEA), including the AIAG-VDA approach, Measurement System Analysis (MSA), Statistical Process Control (SPC) and control plans. Our work focuses on the quality of the analysis, the link between risks and process controls, and the use of data to demonstrate process capability and stability.

Industrialization is where a validated design becomes a stable, capable production process. It is also one of the most critical phases of any program: equipment, people, sub-suppliers and processes must all be ready at the same time, and delays or weaknesses are quickly reflected in launch quality.

We carry out industrialization and production readiness audits, launch audits and supplier readiness reviews, and we support ramp-up with on-site follow-up of process stability, capacity and quality risks. When issues appear, we coordinate containment and corrective actions with the supplier and follow the launch until performance is stable and the supplier can move into regular series production.

Reaching series production is not the end of the process. Changes, new equipment, new sub-suppliers and volume increases can all affect process stability and product quality over the life of a program.

We support organizations in monitoring process performance, analyzing quality issues, managing process changes and strengthening the effectiveness of corrective actions. The objective is a stable process that delivers consistent quality throughout the program.

Every OEM and many Tier 1 suppliers define their own requirements for product and process approval, launch, documentation and escalation. Meeting the standard is not enough if the customer’s specific requirements are not met.

We help suppliers understand and apply the customer-specific requirements of each customer, integrate them into their processes and prepare the evidence that each customer expects. For suppliers working with several OEMs, we help manage different requirements without duplicating work.

Our product and process services are aligned with the methods used across the global automotive supply chain: the AIAG Core Tools, including APQP, PPAP, FMEA, MSA and SPC; VDA-based methods for maturity level assurance, product and process approval and process audits; and the requirements of IATF 16949.

We apply the method that each customer requires, and we help suppliers who work with different customers understand how these approaches relate to each other.