Quality

21 of 28 8D reports blamed the operator: how an automotive welding plant found the real causes

Quality · 3 min read · 19.08.2026

As many as 21 of 28 closed 8D reports in the welding plant blamed the operator. In an audit we uncovered three systemic failures of the method and introduced a rule: a cause is only proven when we can deliberately trigger it and suppress it.

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Reducing Recurring Defects from 40%: How an Automotive Supplier Stopped OEM Complaints

Quality · 3 min read · 12.08.2026

An automotive industry case study. We will show you how we reduced the rate of recurring defects from 40% by restructuring the 8D processes right on the shop floor.

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40 % Repeat Complaints: How an Automotive Tier 2 Supplier Stopped Closing 8Ds on Paper

Quality · 3 min read · 19.08.2026

How we helped an automotive Tier 2 supplier of welded assemblies, where 8D reports closed purely as a formality were leading to 40 % repeat complaints and a threat of CS2 escalation from the OEM customer.

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How to Expand the Supplier Database Without an Increase in Claims

Quality · 5 min read · 30.07.2026

A cheaper supplier on paper means line downtime and fivefold claims costs. At Foreast, we show why formal audits are not enough and how to verify the real process capability.

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Topics: Lean (1)  ·  Quality (4)  ·  Costs (1)  ·  Management (0)  ·  Digitalisation (1)

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