Case study
In 2015, our Director was invited to solve a major quality issue in the assembly of luxury cars. The challenge was to develop a metrology tool that would fundamentally change the way cars were assembled using metrology data.
The manufacturer had lost a very large amount of money during the launch of a previous new model. When cars came off the production line, most failed the quality inspection and audit — despite the company’s robust quality assurance processes.
During the briefing, the programme manager outlined the problems and gave full access to the available metrology data. The objective was clear: to develop a metrology method or tool that would prevent assembled cars failing quality audits and eliminate waste.
With access to component and vehicle body metrology data, our Director analysed defects recorded during the first build of a future vehicle model, refined the approach, and prepared a new metrology analysis tool for the second build.
During the second build, the tool successfully predicted where defects would occur. Non-compliances were identified and rectified before assembly. Out of 18 vehicles, only one predicted non-compliance was detected — and it was flagged before the component even left the supplier.
By introducing new metrology methodologies, the project ensured that no parts were rejected on the assembly line. This leaner, improved process saved the company millions by avoiding rework and waste.
The streamlined process reduced inefficiencies in assembly, data measurement, recording and analysis — proving that efficient processes directly increase profitability.