Mitigating Component Failures

A project was done at an automotive component manufacturing unit. The problem was premature failures in the component. Project team used Design FMEA to identify and mitigate potential failures in the component. Initially, the component faced a 10% failure rate during testing, costing about INR 5 lacs in recalls. The team standardized FMEA processes with templates and trained a cross-functional team. They identified critical failure modes and implemented design changes, reducing the failure rate to 2%. This improvement saved the company INR 1.5 lacs in recall costs and enhanced product safety and reliability, reinforcing customer trust.