Field Operations · SPC Inc.

Your Pain.
Our Response.

We've seen every failure mode a plant can produce. Here's exactly how we answer each one — on-site, with full accountability, from Day 1.

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Supplier CollapseOEM EscalationScrap ReductionDowntime RecoveryDMAIC Execution8D ClosureQRQC Daily ControlLaunch StabilizationSupplier CollapseOEM EscalationScrap ReductionDowntime RecoveryDMAIC Execution8D ClosureQRQC Daily ControlLaunch Stabilization
How We Work

Pain First.
Response Second.

Every engagement starts the same way — we listen to the real problem, not the reported one. Then we respond with specific people, specific tools, and specific accountability.

⚠

The Pain

What your plant is actually experiencing — leadership vacuum, machine downtime, casting defects, CNC variation, missing closures. We name it exactly as it is, without softening the diagnosis.

✔

The Response

A named engineer, a specific methodology, and a defined outcome. Not a proposal. Not a PowerPoint. An execution plan that activates on Day 1 — containment first, root cause second, permanent fix third.

Active Engagement Profile

High-Pressure Die Casting
Supplier Recovery

A Tier-1 aluminum casting supplier serving major OEM programs entered a state of operational collapse. Repeated casting defects, no preventive maintenance discipline, excessive downtime, and a leadership vacuum put critical vehicle programs at risk. This is how SPC/PQTS responded — pain by pain.

⚠ Customer Pain
✔ SPC / PQTS Response
Pain · 01
No leadership. No urgency. The plant is drifting.
The supplier lost its experienced personnel. What remains is a plant with no direction, no daily discipline, and no one who takes ownership of problems. Supervisors react — they don't lead.
↳ Without floor leadership, every other fix is temporary.
→
Response · 01
We walk in Day 1 with ownership mentality — not audit mode.
Our senior manufacturing engineer brings direct shop-floor leadership in die casting, CNC machining, and launch recovery. He doesn't observe — he leads. Our systems engineer installs QRQC as the daily escalation ritual: every open issue has an owner, a deadline, and a verified close.
↳ The plant gets a functioning command structure from Day 1.
Floor Command QRQC Structure
Pain · 02
Preventive maintenance is dead. Machines fail constantly.
PM schedules exist on paper only. Equipment failures are treated as surprises rather than predictable events. OEE is unknown or clearly below target. Availability losses are the single largest source of production loss.
↳ You cannot produce quality parts on machines that fail unpredictably.
→
Response · 02
OEE baseline within 72 hours. TPM recovery roadmap in Week 1.
We execute a downtime Pareto by machine, shift, and failure mode — identifying the top 20% of causes driving 80% of losses. TPM recovery initiates immediately on the highest-impact assets. A live OEE dashboard (Availability / Performance / Quality) is visible to management and client daily.
↳ Downtime becomes a managed metric, not a surprise event.
TPM Recovery OEE Dashboard
Pain · 03
High scrap. Repetitive casting defects. Sorting instead of fixing.
Aluminum castings show porosity, shrinkage, misrun, and cracking. The response has been 100% sort — costly, unreliable, and treating the symptom. The real process root cause has never been formally attacked.
↳ Sorting is not containment. It's a bill that keeps growing.
→
Response · 03
Scrap mapping. Process root cause. PFMEA updated with real data.
Our engineer maps scrap by defect type, machine, die zone, and process parameter — injection pressure, melt temperature, fill time, intensification. We find the actual root cause, not the most comfortable one. The PFMEA is updated with real RPN values and permanent corrective actions (PCA) driven to closure.
↳ Scrap rate drops because we attack the source, not the output.
Die Casting Expert PFMEA / PCA
Pain · 04
CNC instability. Machine-to-machine variation. No process control.
Machined features vary between CNC machines and between shifts. Cpk is unknown or below 1.33. Operators compensate manually with offsets — masking the real variation. There is no statistical process control in place.
↳ Dimensional variation without SPC means quality is a coin flip per shift.
→
Response · 04
SPC on critical characteristics. Cpk ≥ 1.67. MSA on measurement systems.
We implement Statistical Process Control on all critical and significant characteristics, applying Nelson / Western Electric rules. MSA (Gauge R&R) is conducted on key instruments before any Cpk is reported — bad data produces bad decisions. CNC parameters are standardized across machines to eliminate shift-to-shift variation.
↳ Process stability becomes visible, measurable, and defensible to the OEM.
SPC / Cpk / MSA CNC Standardization
Pain · 05
Long changeovers. No time studies. Setup is tribal knowledge.
Die changes and CNC setups consume excessive time with no standard sequence. No documented time studies exist. Setup depends entirely on which operator is working that shift — results are inconsistent and throughput is unpredictable.
↳ Uncontrolled changeovers erode capacity and amplify scrap at every restart.
→
Response · 05
Time studies. SMED methodology. Standardized setup sequence.
Detailed time studies document current-state changeover step by step. SMED methodology separates internal from external activities, identifying quick wins and structural improvements. Standardized tooling kits, visual setup boards, and verified changeover checklists ensure consistent execution — independent of who runs the shift.
↳ Setup time drops and stays down — regardless of who runs the shift.
IE / Time Study SMED Execution
Pain · 06
OEM programs at risk. A shutdown would be catastrophic.
This supplier feeds high-volume, high-visibility programs at multiple OEMs. Any interruption in castings triggers a customer line stoppage. The client cannot afford to let this supplier fail quietly — and neither can we.
↳ Every day without containment is a day closer to a customer shutdown.
→
Response · 06
Field · Shield · Yield activated. The OEM never feels the crisis.
Field = immediate 100% containment and sort of existing inventory — Day 1. Shield = quality firewall at shipping point — nothing leaves that hasn't passed OEM acceptance criteria. Yield = permanent process fix that eliminates the defect source, not just the symptom. The OEM sees stability. The supplier gets a real recovery.
↳ OEM production continues uninterrupted while the supplier recovers.
Field · Shield · Yield
Pain · 07
Problems repeat. Nothing closes. No OEM-ready evidence.
Issues are identified but never formally closed. There is no 8D discipline, no corrective action tracking, and no documented evidence that would satisfy an OEM Supplier Quality Engineer. The same defects return — because the system never verified the fix actually worked.
↳ Repeat failures and missing evidence accelerate OEM escalation.
→
Response · 07
QRQC daily. 8D with evidence. OEM closure package on every issue.
QRQC (Quick Response Quality Control) becomes a daily floor ritual: problem → containment → root cause → corrective action → verified effectiveness. Every issue generates a structured 8D with photo evidence, SPC data, and confirmed closure. The package is OEM-ready — built to the same standard we deliver for Stellantis, GM, and Ford closures.
↳ Every problem closes once — with evidence the OEM can sign off on.
8D / QRQC / Closure Floor Verification
F
Phase 01 · Define + Measure

Field

Immediate on-site deployment. Containment activated within 24 hours. 100% inspection firewall at the source. Downtime and scrap mapping from Day 1.

S
Phase 02 · Analyze + Improve (ICA)

Shield

Root cause analysis with real process data. Interim corrective actions (ICA) installed at every risk point. PFMEA updated. OEM communication managed.

Y
Phase 03 · Improve (PCA) + Control

Yield

Permanent corrective actions validated. Control plan updated. IATF-compliant closure evidence delivered. OEM scorecard recovered.

Your Operation Is
Next on the List.

If your plant is facing any of these pains right now — don't wait for the OEM call. We deploy immediately.

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