Reduction of Scrap Rates for Vehicle Build: Root Cause Analysis & Issue Resolution


Improve third party performance; identify root causes of defects and reduce scrap in vehicle assembly by major North American automotive manufacturer.

By assessing performance and implementing a data-driven rework process, HVM helped the client to successfully reduce scrap for this vehicle assembly.

  • Rear Rail Scrap improvement: 57.7%
  • Sub-Frame Scrap improvement: 68.7%
  • Sub-Frame & Torque Box Scrap improvement: 46.4%

The development of a detailed coining guideline and scrap data tracking tool during this assignment will continue to support quality and consistency.


Implemented rework process to reduce scrap; Developed detailed coining guideline; Established scrap data tracking tool.


  • Managing technical issues at the processor and identifying root causes of defects.
  • Assessing processor capability, quality, and practices; conducted gap analysis, and recommended solutions.
  • Regular and consistent feedback to the plant regarding casting and machining information.
  • Coining operation needed a more thorough understanding of the overall process.
  • Improving the defect specification call-outs process to standardize part acceptability by experienced inspectors as well as new inspectors.
  • This assignment required experience and knowledge in engineering, quality, and manufacturing best practices; required skills in collaboration and communication among team members.
Download Case Study

Supporting Materials

This data represents Bent Rear Rail defects that contributed to the scrap rate. By collecting, organizing, and analyzing this data, we designed a successful rework process.


This is an example of the Coining Guideline and data to show the press bend.


This is a method used for tracking scrap.