Challenge: A significant Tier 1 supplier for General Motors faced persistent issues with their third-party inspection
and containment company (3PIC). Despite ongoing efforts, the previous company failed to adhere to quality
processes, resulting in repeated quality escapes to GM. These continued escapes prompted GM to demand that the
supplier replace the 3PIC immediately. In response, the supplier’s Quality Manager reached out to Talent
Management Group (TMG) for a solution.

Solution: TMG swiftly responded to the supplier’s request and was deployed on a Monday morning. However, over
the weekend, the previous inspection company chose not to support the supplier, leaving a massive backlog of workin-progress (WIP) production. TMG arrived to find the plant in chaos, with product lined up from one end of the facility to the other.

Recognizing the urgency, TMG quickly organized a plan of action:

1. Establishing a Robust Inspection Process:

• TMG collaborated with the supplier’s Quality Manager to create a detailed work instruction
  tailored to the project’s requirements.
• The product required inspection for burn-through welds, with 84 inspection points per part.

2. Rapid Execution and Stabilization:

• TMG’s team divided responsibilities and immediately began working through the WIP backlog,
  ensuring every product met the necessary standards.
• Within three weeks, the team optimized the workflow, reducing the number of associates per shift
  from 15 to 8 while maintaining efficiency and quality standards.

Results: TMG’s intervention resulted in the following outcomes:

• Eliminated Quality Escapes: The implementation of rigorous processes and layered audits completely
  stopped outflows of defective parts to GM.
• Improved Operational Efficiency: Over three weeks, TMG streamlined the inspection process and
  stabilized the project. The number of inspection points was reduced from 84 to 34 through effective root
  cause analysis and process adjustments.
• Removed Controlled Shipping Status: GM lifted the supplier’s-controlled shipping status, a significant
  milestone that restored confidence in the supplier’s quality management.
• Established Data-Driven Insights: TMG provided daily data to support the supplier’s root cause analysis
  and continuous improvement initiatives.

Impact: TMG’s quick action, expertise, and commitment to quality transformed the supplier’s containment and
inspection processes. By eliminating quality escapes and creating a sustainable inspection model, TMG became the
preferred provider for quality inspection and containment services across all the supplier’s plants.

Conclusion: TMG’s success in managing this complex and high-pressure project highlights the value of a wellexecuted quality containment strategy. By combining rapid deployment, tailored processes, and ongoing support,
TMG delivered exceptional results that benefited both the supplier and GM.