How Pro QC Helped Reduce Defect Rates by 40% An Australian automotive manufacturer, recognized for its high-performance brake calipers, contacted Pro QC after experiencing repeated quality issues with a supplier in China. The company needed a dependable way to confirm that every unit complied with its strict technical requirements before distribution to assembly plants and partners. Managing inspections directly from Australia posed several obstacles. With their operations based in Australia, the client faced significant challenges in overseeing inspections. Limited internal resources, tight production timelines, and the high cost of sending their own quality team made it difficult to monitor the supplier effectively. As a result, they turned to Pro QC to solve the situation. The Problem The client experienced persistent quality issues with brake calipers supplied by one of their key factories in China. Initial inspections revealed that over 50% of calipers failed to meet quality expectations. The primary issues were: Paint imperfections: uneven surfaces, scratches, and particle contamination. Logo adhesion issues: adhesive failures caused logos to peel during handling or routine tests. These defects created significant operational problems such as delayed shipments, extra costs for rework and replacements, and growing friction between the client and their supplier. Immediate action was required to restore quality and trust. The Solution Preparation Pro QC designed a tailored inspection process to comprehensively address the situation. The first step was to define a clear inspection scope: Conduct a 100% visual inspection of all brake calipers, focusing on paint quality and logo adhesion. Apply a defect classification system: Critical, Major, Minor, with explicit actions tied to each. Use detailed reporting tools, including high-resolution photos, defect logs, and real-time updates shared with both the client and the supplier. The goal was not just to identify defective units but to provide actionable insights that would guide the supplier toward process improvements. Implementation Our inspectors worked methodically, examining every caliper for potential defects. Each defect was documented with clear images and notes (for example: “Part Number 2345 – Paint Scratch – Failed”), then categorized according to severity. We maintained close communication with the client, sending daily reports that highlighted defect trends and immediate actions. Suppliers were engaged directly, with clarifications provided for any rework requirements. As recurring issues were discovered, the inspection checkpoints were refined—for instance, particle density thresholds were introduced to more precisely define acceptable paint finish quality. The combination of full inspection coverage, clear communication, and data-driven decision-making made the process effective. Daily defect logs not only identified problems but also helped the supplier upgrade their paint application and logo adhesion processes. Solutions Implemented: Standardized defect criteria: visual benchmarks were established for acceptable versus rejected units, ensuring everyone shared the same understanding. Joint review meetings: client, supplier, and Pro QC met regularly to align on expectations and ensure transparency. Process improvements: adhesive rub tests for logos were added, and magnification tools were used to detect small paint particles. Problems We Found and Solved Initial Issues: High defect rates: over 50% of calipers were rejected due to paint or logo issues. Supplier disagreement: the factory initially questioned the defect classifications. Inconsistent standards: subjective judgments on minor versus major defects led to confusion and delays. The Results The impact was immediate and measurable: Defect rates dropped by 40% in subsequent batches. Supplier relationship strengthened: the client renewed the contract with the supplier due to improved quality and consistency. Sustainable inspection model: a repeatable system was established, ensuring future batches meet quality standards without delays. Client Feedback "The detail in the report is fantastic. The team’s attention to detail is excellent." "Clear documentation helped us address issues swiftly." Key Takeaways Challenge: recurring paint and logo defects causing high rejection rates and delivery delays Solution: 100% visual inspection, defect classification, daily reporting, and collaborative supplier alignment Products: brake calipers Location: China Outcomes: 40% reduction in defects, strengthened supplier relationship, repeatable inspection model for future orders About Us Pro QC International is a global quality assurance company with over 40 years of experience in quality. The company is ISO 9001 and ISO/IEC 17020 certified in China and operates local offices in Ningbo, Shanghai, and Shenzhen. Our range of quality control solutions includes quality inspections, factory audits, and supplier management services. Contact us for more information or to request a quote.
