The present work aims at helping the automotive industry reduce warranty. First of all, an equation was developed to predict the warranty Incident per Thousand Vehicle (IPTV) ahead. A study was done to analyze the key points of quality that are related to Production Part Approval Process (PPAP): Design Failure Mode and Effect Analysis (DFMEA), First Time Quality (FTQ), complexity of the part, and Controlled Shipping (CS) to statically show the warranty reduction among different suppliers. Secondly, an Enhanced Production Process was implemented in March, 2016 in a supplier in Mexico. The Enhanced Audit Station ensures that the supplier is enforcing the PPAP requirements. The four most important components are: Touch Appearance Lighting and Color (TALC), Appearance Approval Report (AAR), Dimensional Checks, and Function Testing.
The enhanced process can provide more confidence in the life of a part in terms of producing quality parts and catching any defects that may result from a line move, or sub-tier change. If the supplier sets a process that is implemented at the End of Line (EOL), they will spend more time doing the proposed audit for their component. This will result in earlier identification of defects, parts that are out of tolerance, or parts that do not meet PPAP requirements. This process also might require spending extra money to run testing and can be included in the piece cost, but will save money by reducing warranty and by gaining repeat customers.
