A Tier-1 EV supplier sourcing stamped battery module housings from Korea detected recurring dimensional variation driven by springback deformation. GI established rapid U.S.-side containment to protect production continuity and coordinated a structured corrective-action process across both U.S. and Korean teams. This dual-track approach stabilized incoming quality, aligned measurement criteria, and fully restored dimensional consistency.

Challenge

• • PPM at 420, primarily driven by springback-related deformation
• • Deviation range reached 0.42–0.88 mm (tolerance ≤0.25 mm)
• • U.S.–Korea measurement criteria were misaligned (datum setup, clamping, reference points)
• • 35–42 day transit time increased the urgency for local risk screening
• • No CMM or full GD&T capability at the U.S. warehouse; only light screening possible
• • Tier-1 required a rapid, controlled method to prevent line-impact while corrective actions were underway

GI Solution

GI executed a two-stage solution combining immediate U.S. containment with tightly managed cross-border corrective-action coordination. This ensured uninterrupted production for the customer while driving a structured recovery process.

• ① U.S.-Side Containment & Screening

• ② Cross-Border Technical Alignment & Corrective-Action Coordination

Results

• • PPM reduced from 420 → 60
• • Springback deviation stabilized from 0.42–0.88 mm → 0.18–0.26 mm
• • Zero line-impact during the entire containment period
• • Inspection workflow efficiency improved –38%
• • Measurement alignment established across Korea and U.S. teams
• • Stable delivery resumed within 3 months of corrective-action closure

Client Feedback

​— Senior Program Manager, U.S. EV Tier-1 Supplier