--- title: Case Study: Helping a Global Automotive Supplier Successfully Pass a Toyota New Supplier Audit and Secure New Business description: Learn how a major automotive supplier successfully prepared for and passed Toyota's rigorous New Supplier Evaluation, securing new business with expert guidance from TKD2. image: https://tkd2group.com/hubfs/Factory-to-Forecourt-753x450px-1.jpg --- [Skip to content](https://tkd2group.com/blog/case-study-helping-a-global-automotive-supplier-successfully-pass-a-toyota-new-supplier-audit-and-secure-new-business#main-content) [![TKD2 Group, LLC](https://tkd2group.com/hs-fs/hubfs/logowname.jpg?width=150&height=152&name=logowname.jpg)](https://tkd2group.com/) - [Home](https://tkd2group.com) - Our Company Show submenu for Our Company - [Team Spotlight](https://tkd2group.com/the-team) - [FAQ](https://tkd2group.com/faq) - [Testimonials](https://tkd2group.com/clients) - [LinkedIn](https://www.linkedin.com/company/tkd2group) - [8 Bit Sprint](https://tkd2group.com/game-code) - [2026 Calendar](https://tkd2group.com/2026-events-calendar) - Our Services Show submenu for Our Services - [Business Development](https://tkd2group.com/businessdevelopment) - [Localization Consulting](https://tkd2group.com/localization) - [Nemawashi](https://tkd2group.com/nemawashi) - Product Portfolio Show submenu for Product Portfolio - [Products](https://tkd2group.com/portfolio) - [Gallery](https://tkd2group.com/product-gallery) - Markets We Serve Show submenu for Markets We Serve - [Automotive & Transportation](https://tkd2group.com/automotive-transportation-market) - [Defense & Firearms](https://tkd2group.com/defense-firearms) - [Consumer & Industrial Goods](https://tkd2group.com/consumer-industrial-component-sourcing) - [Aerospace & Drones](https://tkd2group.com/aerospace-drone-component-sourcing) - [Medical & Contract Manufacturing](https://tkd2group.com/medical-component-sourcing-manufacturing) - [Humanoid & Industrial Robotics](https://tkd2group.com/humanoid-industrial-robotics) - [BLOG](https://tkd2group.com/blog) Open main navigation Close main navigation - [Home](https://tkd2group.com) - Our Company Show submenu for Our Company - [Team Spotlight](https://tkd2group.com/the-team) - [FAQ](https://tkd2group.com/faq) - [Testimonials](https://tkd2group.com/clients) - [LinkedIn](https://www.linkedin.com/company/tkd2group) - [8 Bit Sprint](https://tkd2group.com/game-code) - [2026 Calendar](https://tkd2group.com/2026-events-calendar) - Our Services Show submenu for Our Services - [Business Development](https://tkd2group.com/businessdevelopment) - [Localization Consulting](https://tkd2group.com/localization) - [Nemawashi](https://tkd2group.com/nemawashi) - Product Portfolio Show submenu for Product Portfolio - [Products](https://tkd2group.com/portfolio) - [Gallery](https://tkd2group.com/product-gallery) - Markets We Serve Show submenu for Markets We Serve - [Automotive & Transportation](https://tkd2group.com/automotive-transportation-market) - [Defense & Firearms](https://tkd2group.com/defense-firearms) - [Consumer & Industrial Goods](https://tkd2group.com/consumer-industrial-component-sourcing) - [Aerospace & Drones](https://tkd2group.com/aerospace-drone-component-sourcing) - [Medical & Contract Manufacturing](https://tkd2group.com/medical-component-sourcing-manufacturing) - [Humanoid & Industrial Robotics](https://tkd2group.com/humanoid-industrial-robotics) - [BLOG](https://tkd2group.com/blog) - [Contact us](https://tkd2group.com/contact-us) [Contact us](https://tkd2group.com/contact-us) [All posts](https://tkd2group.com/blog/all) March 10, 2026 # Case Study: Helping a Global Automotive Supplier Successfully Pass a Toyota New Supplier Audit and Secure New Business ![Picture of Tom Miller](https://app.hubspot.com/settings/avatar/d41d8cd98f00b204e9800998ecf8427e) By  [Tom Miller](https://tkd2group.com/blog/author/tm)  ·  3 minute read **Client:** Large Global German Automotive Supplier **Facility:** North American Manufacturing Plant (Mexico) **Customer:** Toyota Motor Corporation **Industry:** Automotive Electronics and Electromechanical Components --- **The Challenge** A large global automotive supplier was preparing for a **Toyota New Supplier Evaluation**, one of the most rigorous supplier qualification processes in the automotive industry. Toyota audits evaluate far more than quality metrics. They assess how well a supplier’s manufacturing system aligns with **Toyota Production System (TPS) principles**, including: - Standardized work - Process discipline at the gemba - Traceability and containment systems - PFMEA alignment with production risks - Change management and process control - Special process capability The upcoming audit would include both a full plant operational review and a special process evaluation of welding operations, a process that requires strict process control and statistical capability. Although the facility already demonstrated strong performance metrics, plant leadership recognized that Toyota audits require tight alignment between documentation, floor practices, and operator understanding. To ensure readiness, the supplier engaged  TKD²  to perform an independent operational assessment and prepare the organization for the Toyota audit. ---  **TKD²  Approach**  TKD²  conducted a multi-day operational readiness assessment of the manufacturing facility, evaluating the plant through the same lens used by Toyota Supplier Development engineers. The review included: - Production floor walkthroughs - Documentation and procedure audits - Operator and leadership interviews - Review of PFMEA and Control Plan alignment - Evaluation of traceability systems - Special process review of welding operations - Assessment of Toyota Production System practices at the gemba The objective was to identify any gaps between documented systems and what Toyota auditors would expect to observe on the production floor. --- **Baseline Operational Performance** The facility demonstrated strong operational performance entering the audit preparation phase. **Customer Quality Performance** - **11 PPM customer defect rate** across 15 million parts annually - **0.37 PPM warranty rate** (4 returns in 10.6 million parts) **Supplier Management** - **100% supplier audit completion for four consecutive years** - Supplier audits conducted using **VDA 6.3 certified auditors** **Traceability Systems** - Full SAP-based material traceability - Handling unit traceability including consumables **Process Controls** - 100% automated end-of-line testing - Machine vision inspection at critical stations - Weld monitoring of current, voltage, displacement, and time These metrics demonstrated a highly capable manufacturing operation prior to the Toyota audit preparation process. --- **Risks Identified During the Readiness Review** Despite strong operational performance,  TKD²  identified several areas that Toyota auditors commonly examine closely during supplier evaluations. **Documentation vs. Production Alignment** Certain PFMEA risk entries did not fully align with **actual critical stations on the production line**, creating potential audit concerns. **Visibility of Standardized Work** Work instructions were not consistently visible at all production cells, limiting clarity of standardized work at the gemba. **Scrap Containment Discipline** Some scrap containment areas lacked consistent locking or physical control measures. **Change Management Documentation** 4M change tracking systems were not consistently implemented across production lines. **Consumable Lot Control** Certain production areas allowed potential mixing of consumable lots. These issues did not indicate systemic quality problems, but they represented typical areas where Toyota auditors probe supplier discipline and system maturity. --- **Improvements Implemented**  TKD²  worked closely with plant leadership to implement targeted improvements prior to the audit. **Process Documentation Alignment** - PFMEA and Control Plans updated to reflect **actual production risk points** **Standardized Work Visibility** - Work instructions posted at all production cells - Operator training reinforced with visible standardized work **Quality Containment Improvements** - Scrap handling procedures standardized - Physical containment controls implemented **Change Management Discipline** - 4M change tracking logbooks implemented across production areas **Consumable Traceability** - Improved lot traceability procedures - Smaller container sizes introduced to prevent lot mixing These actions strengthened the plant’s ability to demonstrate **Toyota Production System discipline directly on the production floor.** --- **Special Process Audit Preparation** The Toyota audit also included detailed evaluation of welding operations classified as **special processes**. The facility already demonstrated strong process controls, including: - RFID-based automatic welding parameter loading - Password-protected welding program management - Real-time weld monitoring - Automatic containment of non-conforming welds - Golden and Red Rabbit validation checks  TKD²  supported additional preparation by: - Aligning PFMEA and Control Plans with welding process risks - Improving traceability of welding fixtures - Strengthening documentation of validation checks - Preparing operators to clearly explain process controls during the audit --- **Results** Following the readiness improvements and preparation efforts, the facility successfully completed the Toyota New Supplier Evaluation audit. As a result, the supplier was approved as a qualified Toyota supplier and awarded new production business. The preparation effort ensured the facility was able to clearly demonstrate: - Alignment with Toyota Production System expectations - Strong process discipline at the production floor - Robust traceability and containment systems - Controlled special processes with documented capability The successful audit outcome validated both the plant’s operational capability and the effectiveness of the preparation process. --- **Value Delivered by TKD²**   TKD²  provides independent readiness assessments for automotive suppliers preparing for major OEM supplier audits and new business opportunities. By combining manufacturing expertise with an understanding of Japanese OEM audit expectations,  TKD²  helps suppliers identify and close risks before customer evaluations occur. This approach enables suppliers to confidently demonstrate their operational systems and secure new business opportunities with global OEMs. Have a similar challenge?  Want to chat with our team?  Reach out and talk to Tom or Dan     ![Factory-to-Forecourt-753x450px-1-1](https://242652217.fs1.hubspotusercontent-na2.net/hub/242652217/hubfs/Factory-to-Forecourt-753x450px-1-1.jpg?width=1200&length=1200&name=Factory-to-Forecourt-753x450px-1-1.jpg) Disclaimer: Images, excerpts, links, trademarks, and referenced materials included in this post are used for commentary, education, news reporting, and informational purposes under the fair use doctrine. All rights remain with their respective owners. If you believe any material has been used improperly, please contact us and we will review it promptly. 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 "Anduril Industries")Anduril Industries ![John Deere](https://cdn-ux.deere.com/brand-foundations/2.0.0/logos/jd-logo.svg#green "John Deere")John Deere ![Daimler Truck](https://www.daimlertruck.com/_assets/055a696e49fa76c6e6549e622d95030d/Images/daimlertruck.svg "Daimler Truck")Daimler Truck ![Hyundai](https://na1.hubspot-logos.com/4c15a804-4ad1-4351-a868-6cd42954818a "Hyundai")Hyundai ![Tesla](https://na1.hubspot-logos.com/22a6bca1-84a0-4d14-883d-051bbb2de0ad "Tesla")Tesla ![Cirrus Aircraft](https://na1.hubspot-logos.com/739052e9-e343-4d03-b0ba-78f6986db914 "Cirrus Aircraft")Cirrus Aircraft ![Stellantis](https://www.stellantis.com/content/dam/stellantis-corporate/assets/stell-logo-blue.svg "Stellantis")Stellantis ![FOX](https://na1.hubspot-logos.com/f941d2c4-2a46-483c-8eca-18d3c8aa83f8 "FOX")FOX ![Caterpillar](https://s7d2.scene7.com/is/image/Caterpillar/CM20220222-5c3c2-280a8?fmt=png-alpha "Caterpillar")Caterpillar ![Honda](https://na1.hubspot-logos.com/b9736599-67fc-464d-9ff1-a3955f2b1b84 "Honda")Honda ![Jedco](https://na1.hubspot-logos.com/1d1e5ecd-0138-4373-9f71-cf748b125791 "Jedco")Jedco ![Edelbrock](https://na1.hubspot-logos.com/50c4ee68-c771-4083-8e69-7dde2787cd7a "Edelbrock")Edelbrock ![BorgWarner](https://na1.hubspot-logos.com/275e43be-9964-402c-b614-9e247db53fa2 "BorgWarner")BorgWarner ![VerdeGo Aero](https://na1.hubspot-logos.com/f7307866-b7e7-4615-ba91-cc661260236b "VerdeGo Aero")VerdeGo Aero ![Oshkosh Corporation](https://na1.hubspot-logos.com/f4079bf8-ec8e-4b59-aed3-0686d96a5830 "Oshkosh Corporation")Oshkosh Corporation ![Lucid Motors](https://na1.hubspot-logos.com/b8b7a10b-405a-43ed-bff1-5833cfd46902 "Lucid Motors")Lucid Motors ![Ricardo](https://na1.hubspot-logos.com/fb60aa1f-3e5b-4b04-9ab9-7d1d64520a1d "Ricardo")Ricardo ![Micro Metals](https://transform.octanecdn.com/width/300/https://octanecdn.com/aldermansites/aldermansites_376837011.png "Micro Metals")Micro Metals ![GW 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Copyright © {2021 } Proud members of the [German American Chamber of Commerce](https://www.gaccmidwest.org/us)    & [MEMA, The Vehicle Supplier Association](https://www.mema.org/)   [Privacy Policy](https://tkd2group.com/privacy-policy)   43311 Joy Rd, PMB 427, Canton, MI 48187, USA [linkedin-in icon](https://www.linkedin.com/company/tkd2group/) ![GACC](https://tkd2group.com/hubfs/GACC.jpg "GACC") ![MEMAlogo](https://tkd2group.com/hubfs/MEMAlogo.jpg "MEMAlogo") ```json { "@context" : "https://schema.org", "@type" : "BlogPosting", "author" : { "@type" : "Person", "name" : "Tom Miller", "url" : "https://tkd2group.com/blog/author/tm" }, "dateModified" : "2026-03-10T13:51:33.287Z", "datePublished" : "2026-03-10T13:47:59.000Z", "headline" : "Case Study: Helping a Global Automotive Supplier Successfully Pass a Toyota New Supplier Audit and Secure New Business", "image" : [ "https://tkd2group.com/hubfs/Factory-to-Forecourt-753x450px-1.jpg" ], "mainEntityOfPage" : { "@id" : 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