We work as if we are your company’s own employee engineer by providing engineering-level support and expertise.
Looking to develop your supplier’s quality but not sure where to turn?
Need help with quality recovery or executing quality standards?
Modulus Metal is here to help you develop the quality of your suppliers. Let us guide you with our Resident Engineering services. Any organization can develop its quality with small incremental changes.
Our Services:
-Project Management
-New Production Part Start-Up
-APQP / PPAP Management
-Periodical Supplier Visits
-Nonconformity Management
-Change Management
-Revision Follow Up
-On-Site Measurements and Controls
-PPAP approvals on-site
-Supplier Training for Customer Specifications and Standards on the Engineering Drawings
SERVICE DETAILS
Project Management
We take full ownership of supplier-related quality projects, coordinating all stages from planning to execution. This involves resource allocation, schedule monitoring, risk management, and communication between suppliers and customers. Our role is to ensure every milestone is met without compromising on quality or deadlines, actively identifying potential risks early and mitigating them through effective collaboration with all stakeholders.
New Production Part Start-Up
For new part introductions, we provide comprehensive oversight. We assess tooling, process flow, and capacity to ensure that the production setup can meet required volumes. We work directly with suppliers to optimize production processes, ensuring every step adheres to technical drawings, quality standards, and customer requirements. Our services include trial runs, prototype inspections, and validation of first articles to guarantee the manufacturing line is fully prepared for consistent production.
APQP / PPAP Management
Our APQP process ensures every detail is considered during the planning phase, covering the design and development of both the product and the manufacturing process. This includes detailed reviews of FMEA (Failure Modes and Effects Analysis), control plans, process flow diagrams, and material certifications. We oversee the complete PPAP documentation process, which involves thorough testing, material validation, and the capability of the production process to consistently produce parts that meet specifications. This ensures a flawless transition from development to production.
Periodical Supplier Visits
Regular on-site visits are essential to maintain oversight and control. We schedule these visits periodically to check in on production progress, assess manufacturing conditions, and verify the supplier’s adherence to quality standards. These visits include inspections of the manufacturing environment, process audits, and reviews of any ongoing or anticipated issues that could impact product delivery or quality.
Nonconformity Management
When defects or deviations arise, we quickly step in to manage the issue. Our approach involves detailed root cause analysis, using methods such as 5-Whys and Ishikawa diagrams to understand the underlying problems. Once identified, we implement corrective and preventive actions to resolve the issue and ensure it does not recur. We also follow up with suppliers to monitor the effectiveness of the solutions implemented.
Change Management
Changes in production processes, materials, or design require careful oversight to avoid quality issues. We manage these changes systematically by evaluating the potential impacts on the product and production process. Our team verifies that the changes are implemented without compromising on quality, cost, or delivery. We also update documentation and ensure the supplier’s processes are adjusted to maintain compliance with customer requirements.
Revision Follow-Up
Engineering drawings and specifications frequently change during the course of a project. We track these revisions carefully, ensuring that suppliers receive and understand the latest versions. Our role includes verifying that the new requirements are implemented in production, that tooling is updated if necessary, and that all stakeholders are aware of any potential impacts on the manufacturing process or final product quality.
On-Site Measurements and Controls
We conduct detailed on-site measurements and controls to validate the dimensions and characteristics of parts in real-time. Using precision instruments like CMM (Coordinate Measuring Machines), calipers, and micrometers, we verify that components meet their specified tolerances. This service ensures defects are caught early in production, reducing the risk of defective parts being shipped to customers.
PPAP Approvals On-Site
We expedite the PPAP approval process by conducting on-site assessments, where we review the supplier’s PPAP documentation and perform inspections directly at their facility. This speeds up the validation process, ensuring that parts can enter mass production without delays. We review everything from dimensional reports and material certifications to testing results, ensuring all criteria are met before granting approval.
Supplier Training for Customer Specifications and Standards on Engineering Drawings
To ensure that suppliers fully understand and meet customer-specific requirements, we provide in-depth training on interpreting engineering drawings and applying industry standards. This training includes instruction on tolerance specifications, material requirements, and geometric dimensioning and tolerancing (GD&T). The goal is to equip suppliers with the knowledge they need to produce parts accurately according to customer expectations, reducing the risk of misinterpretation and nonconformance.
This comprehensive approach ensures that suppliers meet quality standards, production runs smoothly, and any issues are addressed promptly, leading to increased efficiency and reliability.
