The challenge
The program ran through a chain the OEM required: Tier 1 supplier, a contract molder in Mexico, then a tool shop in China, both required by Tesla. A Tesla surface (texture) engineer went straight to the tool shop and directed changes to the tools. The modified tools produced bad parts. Bob was flown to China at a day’s notice.
How we investigated
On site, Bob took control of the program and spent three days getting direction back into one channel. He made clear to the molder and the tool shop that they take instructions only from the supplier that owns the program.
What we found
A leather-grain textured cavity had been weld-repaired without color-match welding. The weld showed through on every molded part, a visual defect the OEM would never accept.
The fix
Bob took the program to PPAP with the damaged cavity as a short-term measure and had the tool shop build a new cavity with the correct texture. It reached the molder about two months after PPAP.
The result
The program passed PPAP and the OEM approved the parts while the permanent cavity was built.
The lesson
On offshore programs, steel changes must go through the program owner. Clear channels prevent damage that can take months to undo.
Dealing with something similar?
RFQs, quote comparison, domestic versus offshore builders and program oversight.