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Use CaseJuly 17, 2026
Case Study: Operational Excellence on the Production FloorLocation: Czechia

Context

The customer identified quality challenge which was affecting production. Exact x Forestall was contracted to provide sorting and quality inspection services to ensure that only compliant components were delivered to the production line and the end customer.

Challenge

Our Partner experienced an increased number of non-conforming parts, creating a risk of production downtime and customer complaints. Immediate containment actions and 100% inspection were required to prevent defective components from entering the production process. Furthermore, The internal resources to complete the inspection within the required timeframe were inefficient.

Solution

A dedicated team of trained quality inspectors and a project coordinator was deployed on-site. A 100% visual inspection and sorting process was implemented according to the customer’s quality standards and inspection criteria. Non-conforming parts were identified, segregated, and documented, while inspection results were continuously reported to the customer. Close communication with the customer ensured flexibility and a rapid response to production requirements.

Results

Since 2017, more than 46 million automotive components have been inspected.
More than 2 million non-conforming parts have been identified and contained before reaching production or the end customer.
Over 90,000 quality reports have been prepared.
Project teams have ranged from 20 to 50 quality inspectors, depending on customer requirements and project scope.
100% inspection completed within the required deadline.
Production disruptions successfully prevented.

Services that were used

Quality Inspection
Sorting
Visual Inspection
Rework Support
Quality Reporting
On-site Project Coordination

Confidentiality Notice

Due to restrictions on the client’s side, we are providing only general information.

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