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Quality

Trace defects back

A looming full recall becomes a precise correction before the first customer notices anything.

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In the product

A defect has been reported in component SEN-0743, batch 1400. What is the root cause of the defect? Which products and orders are affected by it? Which actions need to be set in motion?

Batch 1400 (SEN-0743, pressure sensor) comes from SUP-2290 and was tested on testing machine PM-048.

  • Root cause: testing machine PM-048 was running with calibration deviations since early this morning outside tolerance
  • In batch 1400, 321 components across 3 assemblies were installed, of which 2 have already been delivered
  • Affected: 47 customer orders, of which 9 are already in the field with customers

Recommendation: Immediately block batch 1400 in the warehouse, targeted re-inspection of the 9 delivered units instead of a full recall. Root cause can be clearly narrowed down to PM-048.

QuellenPLM · ECR-9842MES · Plant 2/5Service ticketsQM · Test reports

What changes

Before
  • Full recall looming: 11,500 products affected, as the cause cannot be narrowed down.
  • 2 production lines are stopped for 3 days as a precaution until there is clarity.
  • Customer complaints are rising while root-cause analysis drags on.
With d.AP
  • Recall limited at the push of a button to 312 precisely identified units — €4.2 million saved.
  • Series production continues, root cause clearly narrowed down to one machine
  • All 9 affected vehicles proactively contacted on day 1 — before the first complaint.

What it delivers

312units

instead of 11,500

Full recall avoided — narrowed down to exactly the affected units.

0days

instead of 3 days

Line stoppage — through direct identification of the root cause.

9vehicles

previously reactive

Affected vehicles contacted proactively on day 1.

Connected data sources

PLMCAD metadataMESQMService ticketsField reports

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