Case Studies

North American Lighting

General Description

  • At the request of Nissan Motors, TPT dispatched a team of Quality Engineers to work on site at NAL to determine the root cause of numerous quality defects they were experiencing on head light assemblies.
  • TPT provided three seasoned Quality Engineers to rapidly assess the current state process shortcomings and implement corrective actions to improve first time through quality


  • Conducted time studies to develop baseline for process optimization activities and manpower reductions
  • Development of current state standardized work sheets and Yamazumi charts for analysis and the reduction of waste
  • Conducted root cause analysis activities with the plant staff to ensure sustainability of the transformation process
  • Created the future state, standardized work sheets and Yamazumi charts which included waste reduction, quality improvements and optimized process recommendations
  • Developed and supported a training program for the installation of the optimized processes for future state
  • Supported the implementation of the new optimized processes and layout


Within 6 weeks, the TPT QE team identified the root causes of the majority of NAL quality issues and implemented corrective actions for sustainable results

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