A company that made precision parts for a major OEM didn’t have a clear Quality Management System, which led to a steady rise in customer complaints.
Even though they were skilled at manufacturing goods, customers lost trust in them since they didn’t have defined quality processes and their inspection methods weren’t always the same.
The OEM demanded that a firewall inspection system be put in place right away to make sure that faulty parts didn’t reach the consumer.

At this key time, the group partnered with Catalydd Consulting, which is a well-known name in consulting for engineering, quality, and operational excellence.
With Catalydd’s aid with supplier development, process audits, and systematic QMS implementation, the company was able to stabilize its operations and gain back consumers’ trust.

The Issue

The supplier was having a lot of challenges with operations and quality that were making it hard for the firm to stay going:
More complaints from customers and people saying no to products
There is no set way to do inspections or regular job instructions.
Lack of awareness and application of international standards like ISO
There aren’t enough trained quality inspectors.
It’s challenging to hire and keep staff at the factory because it’s in a remote industrial area.
Not having defined quality processes and methods to hold people accountable
They could have lost the OEM as a customer if they didn’t do something.

How Catalydd Consulting Works forQuality Management systems

The purpose of Catalydd Consulting was to create a program that is useful, well-organised, and focused on putting it into action.

Fixing quality problems right away
How to make an effective Quality Management System (QMS)
Helping your internal staff get better at what they do for long-term success
The change has three clear steps:

Phase 1: Setting up the firewall inspection (Immediate Control)

The first step was to make sure there was a good way to verify firewalls so that damaged sections wouldn’t get to the client.
Some important steps were:
Making a specific area for checking firewalls
Writing clear and easy-to-follow work instructions (WIs)
Setting standards for reference samples and visual examination
Setting established daily management boards to keep an eye on the quality of work
Making plans for keeping records and checklists for inspections

Effect: A quick decline in problems related to shipping and better control over the quality of goods sent out.

Phase 2: Setting up a system to keep track of quality (QMS)

Once the immediate dangers were dealt with, the focus shifted to developing a Quality Management System that could grow and was based on processes that met ISO criteria.
Some of the most important projects were:

Making sure that everyone has the same quality processes and paperwork
Adding audits of processes and tiered audits of processes
Setting up systems for centralised quality audits
Daily reviews of operating systems
Ways to solve problems that are organised

To make continuous development even better:
Q-Alerts for big quality issues
8D issue-solving reports help you uncover the root cause of a problem and make sure it doesn’t happen again. One Point Lessons (OPLs) help you learn quickly.
Result: More discipline, openness, and consistency in how things are done.

Phase 3: Teaching Workers New Skills

Catalydd created a special training and skill-building program because they realised that the people who administer systems are what make them strong.

This included:
Planned training sessions for inspectors
Making a list of skills and judging them
Hands-on training that employs standards for visual inspection
Programs that teach people many skills to make operations more flexible
Ongoing training on how to check and control quality
Effect: A workforce that is more skilled, confident, and focused on quality will keep the progress going.

Results Achieved
In a short length of time, the organization saw measurable and long-lasting results:

Fewer complaints from customers by 92%
A considerable improvement in the quality of things that go out
Setting up a QMS that is organised and can grow
Better ways to check things and oversee the process
You have earned the trust of the OEM customer again.
Better ready for additional growth and business in the future.

The organization changed from a reactive quality strategy to a proactive, system-driven manner of conducting business.

The supplier became a more reliable and scalable partner by setting up organised inspection methods, a robust Quality Management System, and training their employees. This made them a more important part of the OEM ecosystem.

Why This Matters for Makers

A lot of businesses that create items have the same problems:
A lot of customers complain
Inspection systems that don’t always work right
No teams trained in quality
Putting ISO-aligned systems in place is hard
These challenges can directly affect keeping clients, developing the business, and making money if there isn’t a plan in place to fix them.

How Catalydd Consulting Can Help

Catalydd Consulting helps OEM suppliers, MSMEs, and manufacturing companies set up operations that are both reliable and scalable in the following ways:

Making a mechanism for checking quality
Putting QMS into action and following ISO standards
Plans for helping suppliers grow
Checks of procedures and activities
Teaching and improving the abilities of the workers

Catalydd has offices in Pune, Chennai, and Faridabad. It works with businesses across the globe to achieve real changes, not merely talk about them.

Want to improve the quality of your systems?

If your business is having trouble with product quality, customer complaints, or processes that aren’t always the same, it could be time to move from mending things as they come up to an organised method.

Contact Catalydd Consulting to find out how a well-thought-out Quality Management System and operational excellence approach may help you become more dependable, get fewer complaints, and confidently grow your firm.