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Praval Technologies

Case study

The parts passed inspection. The defects shipped anyway.

A tier-2 automotive supplier asked us to turn paper inspection sheets into an app. The clipboards weren't the cost; the latency was, and suspect parts left the dock before quality knew.

Less manual data entry
85%Less manual data entryRekeying into the ERP and customer scorecard eliminated
Faster quality containment
40 minFaster quality containmentDown from around six hours, quarantined before dispatch
Lower customer PPM
25%Lower customer PPM

What they asked for

"Build us an app to replace our paper inspection sheets. The clipboards are slowing the line."

The clipboards weren't the cost; the latency was. Quality data reached engineers a shift late, after suspect parts had already shipped to the OEM.

The challenge

Hundreds of line-side quality and machine checks ran per shift on paper, keyed into the ERP and the customer scorecard a shift later. In automotive, a defect that reaches the OEM isn't a return; it's a PPM hit and a risk of stopping the customer's line.

Captured on paper, entered a shift later. Quality data trailed the line by hours; drift was always found after the fact.

Containment stalled in email. A quality hold could sit half a day while suspect stock moved toward dispatch.

The same reading keyed into two systems. ERP and the OEM scorecard, with transcription errors and no live PPM trend.

What we built

Capture at the line. The checks rebuilt as a Power Apps form on a tablet at the station, validated against the control plan, with photos.

Contain in real time. A failed check auto-raises a quality hold in Power Automate, pages the engineer and quarantines the batch, with the audit trail IATF demands.

Connect and assist. Readings flow into the ERP and scorecard with no rekeying, and Copilot answers "what's our PPM trend on Line 3?" in plain language.

The answer wasn't the app. Catching the defect before the truck left was.

Recognise any of this in your own estate?

Start with the problem rather than the technology, and we will tell you honestly whether it is ours to solve.