Automotive · Reactivity Quality

From escalation to permanent fix

Mechatronic system engineers who take over your quality escalations,
contain the issue and lead customers, suppliers and technical teams to the definitive solution.

Talk to an expert See cases
50
engineers and system specialists
10y
average automotive experience
30+
vehicle programmes supported

Bridge · Fix · Lead

One contact from first report to closure.

Bridge teams to solutions

We connect customer, suppliers and Body, SW, HW and EE teams: one single contact and one single action plan.

Fast fix, final fix

An interim solution protects production and quality KPIs right away; the permanent corrective action removes the root cause.

Lead to closure

We drive the diagnosis and lead customer and suppliers until the issue is closed, with clear timing and constant reporting.

Defined response times

Four steps, each with a committed time.

  1. 1
    < 2h

    1 · Take-over

    Escalation call answered and case opened with a dedicated contact.

  2. 2
    24h

    2 · Analysis and alignment

    First failure analysis and action plan shared with customer and supplier.

  3. 3
    1 week

    3 · Interim solution (ICA)

    Containment in place: sorting, rework, deviation or SW workaround to protect the line.

  4. 4
    1 month

    4 · Permanent fix (PCA)

    Root cause confirmed, corrective action with owners and dates, weekly follow-up until closure.

Production block? Priority activation, dedicated contact and continuous updates until the line is running again.

Technical scope

Expertise on mechatronic systems.

Families of mechatronic components with development and serial-life know-how.

Controls and switches

Steering-wheel controls, door switches, Engine Start/Stop, drive mode selector, joystick

Steering wheel controls

Vehicle access

E-latch, electric door handles, power mirrors, hands-free sensors

Door handlePower mirror

Powertrain and chassis

Automatic gear shifter, pedal box, clutch and accelerator sensors, active anti-roll bar

Gear shifterPedal box

Sensors and security

Rain and light sensor, TPMS, accelerometers, anti-theft siren

Rain and light sensorTyre pressure sensor

Body and aerodynamics

Sunroof, active spoiler, active grille shutter, charging flap, tailgate spindles

Car bodyActive grille shutter

Lighting

LED headlamps and rear lamps, DRL, small exterior lighting, interior lighting

Headlamp

Real cases

Exterior door handle · field quality

Door does not open when the customer pulls the exterior handle

▲ –80% customer claims after the interim action; case fully closed with the permanent fix.

Root cause: the lever spring cracks after 35–38k cycles, due to the elastic deformation of the paddle. A design issue was confirmed and a supplier process issue ruled out.

Fix: an additional spring as interim action, then a spring redesign (calculation, CAD, FEM) as permanent action.

Sunroof SW · network · SOP

Network file out of sync at SOP

▲ Customer claims avoided; SW released and validated in 4 weeks, SOP protected.

Root cause: the LIN database file contained a master–slave misalignment. The auto-addressing process had changed, and the supplier had not implemented the related requirement.

Fix: SW updated, validated on vehicle and released in 4 weeks, with no impact on SOP.

Have an open quality issue?

Tell us the system or component and the symptom. An engineer replies within two working hours.

segreteria@bflengineering.com

Confidentiality and NDA

We work under NDA with every customer. Technical data, specifications, logs and returned parts are used only to resolve the case, shared only with the people involved and never disclosed to third parties.

Privacy notice

Personal data sent through this form are processed by BFL Engineering [legal form], as data controller, only to answer your request, in line with EU Regulation 2016/679 (GDPR). Data are kept for [24 months] and never sold. You can ask to access, correct or delete them at any time by writing to privacy@bflengineering.com.