Locations: Ennore, Hosur, Alwar, Pant Nagar (Uttarakhand)
Scope : Outsourcing Activities in Production and Quality Assurance for Commercial Vehicle Division (LCV, MCV & EV Buses)
Engagement Start : Ongoing
Focus : Meeting Specifications & Customer Requirements
The Challenge
Our Client, one of the largest manufacturers of commercial vehicles in India, operates across a vast network of production plants spread throughout the country. The company faced the challenge of maintaining consistent quality and timely delivery of vehicles, including LCVs, MCVs, and EV buses, amidst fluctuating production volumes and model mixes.
To address these challenges, Client partnered with Layam Group for outsourced operations in critical areas of Production, Quality Assurance
(VQA), and Field Quality Assurance (FQA). The key objective was to ensure zero defects, Build-In Quality, and 100% delivery across plants in Ennore, Hosur, Alwar, and Pant Nagar.
The Layam Solution
Layam Groupʼs expertise lies in managing large-scale operations efficiently while ensuring high-quality outputs. Our teams at each of Clientʼs plants focus on both production processes and quality assurance with an emphasis on continuous improvement, on-time delivery, and customer satisfaction.
The Challenge
Our Client, one of the largest manufacturers of commercial vehicles in India, operates across a vast network of production plants spread throughout the country. The company faced the challenge of maintaining consistent quality and timely delivery of vehicles, including LCVs, MCVs, and EV buses, amidst fluctuating production volumes and model mixes.
To address these challenges, Client partnered with Layam Group for outsourced operations in critical areas of Production, Quality Assurance
(VQA), and Field Quality Assurance (FQA). The key objective was to ensure zero defects, Build-In Quality, and 100% delivery across plants in Ennore, Hosur, Alwar, and Pant Nagar.
The Layam Solution
Layam Groupʼs expertise lies in managing large-scale operations efficiently while ensuring high-quality outputs. Our teams at each of Clientʼs plants focus on both production processes and quality assurance with an emphasis on continuous improvement, on-time delivery, and customer satisfaction.
Key Strategic Deliverables
- Daily Production Reports to track manufacturing progress and issues
- Quality Reports on Defects Per Vehicle (DPV) and Vehicle Audit Trends to monitor and mitigate quality concerns
- Safety Reports ensuring a secure work environment
- Training Records to document and ensure skills development
- Monthly Production Reports to summarize key metrics and achievements
- Kaizen/A3 Reports for continuous improvement and problem-solving
Our Expertise in Vendor Quality Assurance (VQA)
Layamʼs teams play a crucial role in ensuring quality at every step of the production process. This involves:
- Expert Inspection, Testing and Measurement of incoming parts to ensure compliance with specifications
- Thorough Vendor Shop Process Inspection to detect any potential quality issues before they reach the production line
- Rapid Investigation of Line Issues with a proactive approach to escalate issues to vendors for ICA (Initial Corrective Action) and PCA (Permanent Corrective Action)
- Skill Development through Job Rotation and continuous training programs to enhance the workforceʼs abilities
- 5S Implementation and Safety Norms Compliance at all plants, ensuring a Zero Incident/Accident Environment
- 98% Adherence to Parts Inspection Plan, ensuring quality standards are met consistently
- Vendor Audits to enhance the system, process, and product quality at the source
Our Expertise in Vendor Quality Assurance (VQA)
Layamʼs teams play a crucial role in ensuring quality at every step of the production process. This involves:
- Expert Inspection, Testing and Measurement of incoming parts to ensure compliance with specifications
- Thorough Vendor Shop Process Inspection to detect any potential quality issues before they reach the production line
- Rapid Investigation of Line Issues with a proactive approach to escalate issues to vendors for ICA (Initial Corrective Action) and PCA (Permanent Corrective Action)
- Skill Development through Job Rotation and continuous training programs to enhance the workforceʼs abilities
- 5S Implementation and Safety Norms Compliance at all plants, ensuring a Zero Incident/Accident Environment
- 98% Adherence to Parts Inspection Plan, ensuring quality standards are met consistently
- Vendor Audits to enhance the system, process, and product quality at the source
Our Expertise in Field Quality Assurance (FQA)
Field quality concerns require swift and effective resolution. Layam ensures that FQA is handled with speed and precision through:
- 24/7 Customer Incident Site Visits across India, ensuring fast response times for any quality-related complaints
- Local Site Response within 1 Hour and Outstation Site Response within 2 - 3 Hours, prioritizing customer satisfaction
- Thorough Investigations into customer complaints to prevent recurrence and ensure no repeat issues within 15 days
- Day and Night Response : Between 6 AM to 10 PM (Day) and 10 PM to 6 AM (Night) ensuring round-the-clock support
- Resolution within 24 Hours, ensuring minimal downtime for vehicles and customer inconvenience
- No Repeat Complaints for the same failure mode, with less than 15 days between incidents
Results & Impact
- 100% Delivery on time despite fluctuations in volume and model mix
- Zero Defects per Vehicle through comprehensive quality control and process audits
- Improved Production Efficiency through proactive issue resolution and Kaizen-driven improvements
- Reduced Downtime with 24/7 FQA support ensuring quick resolution of customer complaints
- Safety First : Achieved a Zero Incident/Accident record across all plants
- Skill Development : Continuous upskilling of workers, especially welders, ensuring a skilled workforce
- Proactive Vendor Management : Enhanced quality of sourced parts through regular inspections and audits
Results & Impact
- 100% Delivery on time despite fluctuations in volume and model mix
- Zero Defects per Vehicle through comprehensive quality control and process audits
- Improved Production Efficiency through proactive issue resolution and Kaizen-driven improvements
- Reduced Downtime with 24/7 FQA support ensuring quick resolution of customer complaints
- Safety First : Achieved a Zero Incident/Accident record across all plants
- Skill Development : Continuous upskilling of workers, especially welders, ensuring a skilled workforce
- Proactive Vendor Management : Enhanced quality of sourced parts through regular inspections and audits