After years of conducting quality audits for automotive Tier 1-3 suppliers, the same five issues show up in almost every plant we walk into.

1. Calibration gaps — Gauges are out of cal, records are missing, and nobody owns the schedule. This is a finding on every single IATF audit.

2. PFMEA disconnected from Control Plans — The PFMEA says one thing, the Control Plan says another, and the floor is doing something completely different. Auditors catch this in minutes.

3. No reaction plan execution — You wrote reaction plans in your Control Plan but nobody on the floor knows what to do when a process goes out of spec.

4. Training records that don't match job requirements — Operators are running processes they were never formally trained on. This is a liability and an automatic finding.

5. Corrective action = containment only — 8Ds that stop at D4. No root cause analysis, no systemic fix, no validation of effectiveness. Your customer sees right through it.

If any of these sound familiar, your next OEM audit is going to be painful. We help Tier 1-3 suppliers fix these gaps before they become customer escalations.