Valeo: Task Force Quality & Quantity - TMAP Sensor for Audi AG

The Challenge

Valeo faced a critical escalation from OEM Audi AG regarding TMAP sensor production. Quality and quantity issues in the manufacturing processes for potting and soldering were threatening the supply chain and customer relationship, requiring immediate intervention and process improvement.

Our Solution

We deployed a dedicated Task Force as program and team lead with 10 team members. Our approach combined rigorous process audits in accordance with VDA 6.3, selection of new potting materials, comprehensive process engineering for potting (epoxy) and soldering, along with continuous action tracking and coaching.

Our Approach

• ✓ Established program and team leadership with 10 team members
• ✓ Executed process audits in accordance with VDA 6.3
• ✓ Selected and qualified new potting material (Epoxy)
• ✓ Optimized soldering process parameters and quality
• ✓ Implemented comprehensive action tracking system
• ✓ Provided coaching and knowledge transfer to local teams

The Results

• ✓ Successfully de-escalated the critical OEM situation with Audi AG
• ✓ Improved potting and soldering process quality
• ✓ Qualified new potting materials for production
• ✓ Established sustainable process controls and monitoring