Case Study: 35% Less QC Rejection for Forging Unit
The Challenge: High Rejection with No Way to Find the Cause This forging unit had been operating for 18 years and supplied automotive Tier-1 and Tier-2 customers across Gujarat and Maharashtra. Their engineering quality was solid — their production team knew their craft. But their rejection rate had crept up over the previous two years, and nobody could pinpoint why. The fundamental problem was a data problem. When a batch of components failed inspection — either internally at final QC or at the customer's incoming inspection — there was no systematic way to trace back what had gone wrong. The paper job cards from the relevant production run might or might not be retrievable. The heat records from the furnace were in a separate logbook. The die condition at the time of forging was undocumented.
