Impact damage on housings — one meeting on the floor, defect rate down 90%

Problem
A German Tier-1 flagged impact marks on aluminium housings. Defect rate near 10%, the batch at risk, the line needing 1,000 parts a day. Cosmetic standards did not match.
What we did
On site the next day. Sorting first, to keep the line. Then walk the assembly, separate sealing faces from surfaces that disappear after fit, and reset the standard.
Result
Cosmetic rules relaxed on non-visible faces. Defect rate fell by more than 90%. The line did not stop.


