Locations: Hosur & Ennore
Focus Areas: Chassis Assembly Line & Vehicle Testing System (VTS) Line
Manpower : 350+ Layam Employees
Objective : Achieve a DPV of 0.2 at Firewall & 0 MIS with Zero Delivery Delays
The Challenge
Our Client, a pioneer in commercial vehicle manufacturing, aimed to achieve world-class quality standards in its Chassis and VTS Lines at Hosur and Ennore plants. With an intense production schedule, maintaining consistent Build-In Quality (BIQ) while reducing Defects Per Vehicle (DPV) and ensuring Zero Misses (0 MIS) posed a significant challenge.
To meet these quality and production goals, Client partnered with Layam
Group, leveraging our proven expertise in Quality Inspection, Process Excellence, and Skill-Based Workforce Deployment.
Layamʼs Role
Our 350+ strong Layam team deployed across Hosur and Ennore facilities plays a key role in Chassis Assembly and Vehicle Testing, ensuring the highest level of output quality with zero compromise.
The Challenge
Our Client, a pioneer in commercial vehicle manufacturing, aimed to achieve world-class quality standards in its Chassis and VTS Lines at Hosur and Ennore plants. With an intense production schedule, maintaining consistent Build-In Quality (BIQ) while reducing Defects Per Vehicle (DPV) and ensuring Zero Misses (0 MIS) posed a significant challenge.
To meet these quality and production goals, Client partnered with Layam
Group, leveraging our proven expertise in Quality Inspection, Process Excellence, and Skill-Based Workforce Deployment.
Layamʼs Role
Our 350+ strong Layam team deployed across Hosur and Ennore facilities plays a key role in Chassis Assembly and Vehicle Testing, ensuring the highest level of output quality with zero compromise.
Key Inspection Touchpoints in the Chassis Assembly Line
Frame Assembly → Q-Gate 1 → Q-Gate 2 → Q-Gate 3 → PIT → End of Line (EOL) OFF TRACK → Smoke Test → Pre-Delivery Inspection (PDI) → VTS Gate 1 → Paint Booth → VTS Gate 2 → Sales Yard
Each point is staffed by trained Layam professionals, focusing on error-proofing, timely escalation and quality control at every stage.
Reports Generated
- Attendance Reports - Ensuring operational continuity through real-time manpower tracking
- Delivery Performance Reports - Monitoring on-time completion and dispatch
- Customer Complaint Reports - Immediate capture, response, and resolution
- Defects List - Real-time defect capturing for proactive interventions
- Pareto Analysis - Data-driven prioritization of defect categories
- Root Cause Analysis (RCA) - Actionable insights leading to Permanent Corrective Actions (PCA)
Reports Generated
- Attendance Reports - Ensuring operational continuity through real-time manpower tracking
- Delivery Performance Reports - Monitoring on-time completion and dispatch
- Customer Complaint Reports - Immediate capture, response, and resolution
- Defects List - Real-time defect capturing for proactive interventions
- Pareto Analysis - Data-driven prioritization of defect categories
- Root Cause Analysis (RCA) - Actionable insights leading to Permanent Corrective Actions (PCA)
Noteworthy Achievement
Layamʼs dedication and operational excellence contributed significantly to
Client receiving the prestigious Deming Award – a testament to our relentless focus on process quality, people efficiency, and zero-defect delivery.
Our Expertise in Vehicle Production & Build Quality
- Achieving Production Plan & Sequence Plan with 100% Productivity
- Control on DPV (Defect Per Vehicle) & DPC (Defect Per Cab) through multi-level inspection
- Continuous Training via
- On-the-Job Training (OJT)
- Classroom Training (Technical - Part & Vehicle Level)
- Soft Skills Development
- Job Rotation Programs
- Manpower Planning & Availability to avoid production downtime
- Immediate & Permanent Actions on vehicle audit findings and customer field complaints
Our Expertise in Vehicle Production & Build Quality
- Achieving Production Plan & Sequence Plan with 100% Productivity
- Control on DPV (Defect Per Vehicle) & DPC (Defect Per Cab) through multi-level inspection
- Continuous Training via
- On-the-Job Training (OJT)
- Classroom Training (Technical - Part & Vehicle Level)
- Soft Skills Development
- Job Rotation Programs
- Manpower Planning & Availability to avoid production downtime
- Immediate & Permanent Actions on vehicle audit findings and customer field complaints
The Outcome
- Reduced DPV to target 0.2 at Firewall
- Zero Misses (0 MIS) reported over extended periods
- 100% on-time deliveries without compromising on quality
- Enhanced workforce skill levels through structured training modules
- Streamlined defect traceability, RCA, and feedback loops
Why It Matters?
Layamʼs model showcases how a people-first, process-driven approach can drastically improve production efficiency and vehicle quality, especially in high- volume automotive environments. Employers benefit from:
- Zero Production Stoppages due to skilled and standby manpower
- Data-Backed Quality Management ensuring customer trust
- Proactive Defect Control mechanisms across all checkpoints
- Field Complaint Resolution with speed and accountability