Automek a large multinational auto component manufacturer headquartered in North America with plants worldwide. It supplied complete systems to many car manufacturers globally. This particular project was the first time that it had supplied components to OEM. Automek was looking forward for more business form OEM if this was successful.
Due to increasing cost in the United States, Automek was on a lookout for global low-cost source. During its search it came across Agile in India and sent its technical team to assess this potential supplier. The team was satisfied with the facility and approved it as its supplier of motors to Automek.
As Agile’s quality and delivery performance was good. In 2002 Automek awarded a business for a new product which was not in Agile’s existing product portfolio. A team was deputed to work with Agile to setup the manufacturing line to produce the product as per Automeks requirement. The launch was successful and Agile continued to deliver Zero defects or delivery defaults.
Based on previous track record Agile was selected to supply new actuator assembly and they had no experience in this.
As done earlier, Automek is not deputing any engineers to work with Agile. They accept to process the in house parts. For critical components Agile approach Automek for support as they no idea on the parts.
Agile recommends ECPL who was also an existing supplier to them. The Automek team audited ECPL and gave a go-ahead to ECPL with some gaps to be addressed.
ECPL recommended BIPL for supplying of PCB. Automek agreed as BIPL was an ISO 9000 certified company. After auditing the recommended some gaps and gave a go-ahead for development.
Problem
There were a failure reported by the Ford which seemed to originate from the actuator assembly supplied by Agile. Automek asked Agile to investigate the problem and report on root cause of the problem. In 2009 Automek deputes its Process expert to work on the problem. After series of