Solving Inconsistency in Quality: Aerospace Sub-System Manufacturer
Our client struggled through the Production Part Approval Process (PPAP) and failed to meet the stringent quality standards required for aerospace components. As a result, the manufacturer experienced severe disruptions and TQ Manufacturing was involved
Client's Pain point & need
A long-time customer in the aerospace industry sought to reduce costs by outsourcing their machining work to a lower-cost vendor. TQ Manufacturing had been involved in the quoting process but ultimately lost the bid due to price considerations. However, the selected vendor struggled through the Production Part Approval Process (PPAP) and failed to meet the stringent quality standards required for aerospace components. As a result, the manufacturer experienced severe disruptions:
- Defective Parts: The vendor shipped non-conforming parts, causing assembly failures during testing.
- Production Delays: The need for rework and corrective actions led to missed deadlines and increased lead times.
- Escalating Costs: Additional inspections, material waste, and overtime expenses negated any initial cost savings from choosing the low-cost supplier.
- Reputation Risk: The quality issues created concerns among the manufacturer's end customers, threatening their credibility in the industry.
How TQ Helped:
Recognizing the challenges their customer faced, TQ Manufacturing proactively continued working on PPAP orders for the same components in parallel. This strategic move ensured that a reliable solution was ready when the customer needed to pivot.
To resolve the quality issues, TQ implemented its rigorous ISO 9001-certified quality control processes, integrating:
- Advanced Inspection Technology: Utilization of CMM (Coordinate Measuring Machine), optical inspection systems, and in-process quality verification to ensure every part met exact specifications.
- Tight Process Controls: Standardized machining and finishing procedures to maintain consistency across production runs.
- Continuous Communication: Frequent updates and transparent reporting to keep the customer informed throughout the transition.
Once TQ Manufacturing successfully passed the PPAP requirements, production orders commenced seamlessly, delivering fully conforming parts without a single quality issue.
Outcome:
By transitioning their production work to TQ Manufacturing, the aerospace customer eliminated the risks and costs associated with defective parts. Over the last 12 months, they have reported:
• Zero Part Defects: TQ’s superior machining and quality assurance processes ensured 100% compliance with specifications.
• Increased Operational Efficiency: The customer’s assembly lines ran smoothly without disruptions from rework or delays.
• Cost Savings Without Compromise: While the initial vendor was chosen for cost reduction, the hidden costs of defects and delays proved far more expensive. TQ delivered high-quality parts while maintaining cost efficiency.
• Production Ramp-Up Success: With consistent and reliable part supply, the customer was able to scale production of their aerospace sub-system without concerns about component failures.
How Can TQ Manufacturing Help Your Operation?
If you’re struggling with supplier quality issues or need a trusted machining partner that delivers precision and reliability, TQ Manufacturing is ready to help.
📩 Email us today to discuss how we can enhance your manufacturing operations with superior quality and on-time delivery.