For automotive Tier-1 and Tier-2 manufacturers
Certified on paper. Different on the floor.
IATF 16949 consulting and training that turns written procedures into shop-floor practice. Your system already exists on paper. Together with your team, we make it run on the floor.
Does this sound familiar?
Most plants have the certificate, the manual and the procedures. Walk the line, though, and the floor often tells a different story.
A customer audit is coming
and you're not sure the floor will match the documents.
Your team has been trained
but the line still works the old way.
The same findings keep coming back
control plans, MSA, corrective actions.
That gap is where defects, escalations and repeat findings come from. It's also where we work, side by side with your team.
Check. Fix. Make it stick.
- CheckWe walk your floor against your paper: control plan, PFMEA, MSA, work instructions. You get a clear picture of where they don't match, and why.
- FixWe close the gaps together, with your team doing the work. Not a consultant writing documents in a back office.
- Make it stickHands-on training on real parts and data, so the team uses it back on the line.
Where to start
Not sure where to begin? Start with a Paper-to-Floor Check.
One or two days on your floor, comparing what your system says with what actually happens. You get a gap map with priorities. No long contract, and you decide what to do next.
Make it work
Consulting
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Paper-to-Floor Check
One or two days on your floor: see where your IATF system and your shop floor don't match, with a gap map and priorities.
How it works -
IATF 16949 Implementation
IATF 16949 implementation for automotive suppliers in India: a system built around how your plant actually runs.
How it works -
Audit Findings Closure
Close IATF audit findings for good: root causes and corrective actions that hold.
How it works -
QRQC Implementation
QRQC implementation for automotive plants: react to quality problems the same day, on the floor, with the real part and real data.
How it works -
FMEA & Control Plan Review
PFMEA, DFMEA and control plan review against the real process, in AIAG or AIAG-VDA format.
How it works -
Supplier Audits
Pre-award and process audits of automotive suppliers, focused on the floor, not just the files.
How it works
Make it stick
Training
Practised on a defined sample part and the free simulators. For in-plant programmes, we can build the examples around your own parts and process.
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Core Tools Training
All the automotive core tools in one course: APQP, FMEA, control plan, MSA, SPC and PPAP, as a 2-day awareness or a 5-day practitioner workshop.
See the programme -
SPC Training
Hands-on SPC training: control charts, signals, and Cp, Cpk, Pp and Ppk, using a live simulator.
See the programme -
MSA Training
Measurement System Analysis training: gauge R&R, bias, linearity, attribute studies, applied to your gauges.
See the programme -
FMEA Training (AIAG-VDA)
PFMEA and DFMEA training in the AIAG-VDA method or AIAG format, with your own process.
See the programme -
Control Plan Training
Control Plan training: link PFMEA risks to the checks actually done on the line.
See the programme -
APQP and PPAP Training
APQP and PPAP training: launch new parts without surprises, with fewer PPAP rounds.
See the programme -
Problem Solving Training: QRQC, 8D, A3, 5 Why
Problem-solving training from same-day QRQC on the line to 8D for customer complaints.
See the programme -
IATF 16949 Internal Auditor Training
Three-day IATF 16949 internal auditor training: process-approach audits that find what breaks the flow.
See the programme
Notes from the shop floor
Latest articles
Free tools
Learn it by doing it.
Free SPC, MSA and FMEA simulators with short lessons, one step at a time. No sign-up, made for engineers and operators alike.
15+ years inside automotive plants.
Manoj has worked in quality from a Tier-2 machining and die-casting supplier to Tier-1 wiring harness plants (Motherson Sumi, Aptiv) and an OEM engineering centre (Renault Nissan). As management representative, he took two plants through IATF 16949, ISO 14001 and ISO 45001 certification without outside consultants.
Today Kattamaipu helps plants build quality systems that people actually use, not systems written only for the auditor.
IRCA-certified Lead Auditor courses (ISO 9001, 14001, 45001) · IATF 16949 Lead Auditor course · Lean Six Sigma Black Belt · Based in Chennai, working across India
Founder, The Kattamaipu Company
Let's talk about what's happening on your floor.
A short message is enough. You'll get a reply within one working day.