Record-Low Incidents & IATF Audit Clean-Sweep
BorgWarner
Achieved the lowest number of customer quality incidents in 10+ years.
Challenge
QMS had many gaps, driving poor internal, supplier, and customer quality metrics.
Large number of IATF non-conformances created audit risk.
Actions
Created a Quality Department Scorecard and requirements vs. evidence matrix for IATF audits.
Drove gap analysis to closure systematically.
Rolled out 8D and problem-solving training for all quality engineers with checks and balances.
Implemented focus supplier groups to drive quick actions on struggling suppliers.
Results
Within one year, met all Quality Department metrics.
Achieved the lowest number of customer quality incidents in 10+ years.
IATF audit results improved from probationary levels to only a couple of minor non-conformances in under one year.
Focus supplier groups improved yield and throughput internally and across the supply base.