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Client
U.S. heavy equipment OEM
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Supplier
Korean forging & machining partner
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Location
Korea → U.S. Midwest
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Service Type
Supplier Discovery & Verification
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Duration
6–12 weeks
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Outcome
0.6% defect, ±1.8 HRC stability, 6–7 week lead time
A U.S. heavy equipment OEM experienced ongoing hardness variance and defect rates from overseas forging suppliers. GI identified a qualified Korean forging partner, validated heat-treatment capability, and established a stable quality-control and delivery model.
Challenge
- • Heat-treatment deviation ±5–7 HRC (OEM spec: ±2 HRC)
- • Defect rate 3.8% across two years
- • Lead time fluctuation 9–11 weeks
- • 100% UT/MT required for shafts
- • Monthly volume 2,000–3,500 pcs
GI Solution
- ① Supplier Discovery & Capability Verification
• Evaluated 11 Korean forging shops; shortlisted 3
• Verified furnace uniformity, quench repeatability, and HT cycle simulation
• Assessed machining capability for OD tolerance, runout, and keyway conformity
- ② Pilot Run & Quality Stabilization
• Coordinated a 500-piece pilot run
• Verified 100% UT/MT pass
• Introduced calibration SOPs and basic SPC tracking to ensure repeatability
- ③ Delivery Stabilization
• Implemented a structured cycle yielding 6–7 week predictable lead time
• Added a 4-week safety stock model to offset port and logistics variability
Results
- • Defect rate: 3.8% → 0.6%
- • HT variance: ±1.8 HRC
- • Lead time: 9–11 → 6–7 weeks
- • UT/MT: 100% pass
- • Cost impact: –9% to –11%
Client Feedback
— Supplier Quality Manager, U.S. Heavy Equipment OEM
“The improvement in HT variance and defect rates was significant. GI’s coordination with the Korean forging supplier gave us the stability we had been trying to achieve for years.” |
