Quality & Defect Intelligence

Hargate Precision Components – Chattanooga, TN • Automotive Tier 1 Supplier • Week 12, 2024

North Star

$47.32

Gross Margin/Unit

First-Pass Yield

94.2%

+1.8pp WoW

COPQ

$127K

-$18K WoW

Avg Cpk

1.42

+0.11 WoW

Customer Escape

42 ppm

-29 ppm WoW

Scrap Cost

$31K

-$7K WoW

Rework Labor %

6.2%

-1.1pp WoW

Cost of Poor Quality Waterfall – Week 12

First-Pass Yield by Product Family (12-Week)

Defect Rate by Supplier Lot (ppm)

Process Capability Index (Cpk) by Machine-Station – Week 12

CNC-01

CNC-04

Weld-02

Assembly-3

Harness-A

Inspect-1

Powertrain

1.68

1.08

1.52

1.33

1.21

1.71

Brake Module

1.59

0.94

1.38

1.47

1.19

1.63

Chassis Bracket

1.74

1.41

1.55

1.28

1.24

1.69

Harness-EV

1.61

1.35

1.44

1.49

1.58

1.66

Cpk < 1.0 (Critical)

1.0–1.2 (Warning)

1.2–1.33 (Acceptable)

1.33–1.5 (Good)

> 1.5 (Excellent)

Defect Pareto Analysis – Top 10 Modes (Week 12)

Supplier Quality & Warranty Intelligence

Supplier	Latest Lot	Defect ppm	Δ vs Avg	Top Defect Mode	Warranty Claims	Status
Supplier C	Lot 4471	1,187	+948	Dimensional OOT	23	8D Active
Supplier A	Lot 4489	142	-31	Surface Finish	7	Approved
Supplier B	Lot 4502	218	+47	Coating Thickness	12	Monitor
Supplier D	Lot 4481	89	-18	Thread Quality	3	Approved
Supplier E	Lot 4497	305	+112	Weld Porosity	18	CAR Issued

Warranty Claims by Generation

Audit Non-Conformance Closure

Defect Concentration (Top 5)

Dimensional OOT 28.4%

Surface Finish 19.7%

Weld Porosity 15.2%

Thread Quality 12.1%

Coating Thickness 9.8%

Total (Top 5) 85.2%

Customer Escape Rate – 12-Week Rolling (ppm)