Quality & Operational Performance at Scale
“We’re shipping defects our own data should have caught.”
Connecting design, manufacturing and supply chain data into decisions — eliminating defects, modernizing the systems that hide them, and building engineering discipline that holds.
Almost every organization that ships a physical product already holds the data that would have predicted its worst defect. It is in warranty claims, test results, supplier quality records and field telemetry. What it is not in is one place, at one time, in front of the person who could still have done something about it.
So quality becomes a department that inspects rather than a property of how the work is done, and the same failure modes recur program after program — because nothing connects the evidence from the last one to the design of the next.
We connect those sources and then change what happens when they disagree with the plan. The measure of this work is not a dashboard. It is a defect that does not reach a customer, and a warranty line that comes down and stays down.
Where AI fits here
Includes the AI that genuinely pays here — pattern detection across warranty, test and field data — and the data quality it depends on, which is the layer most programs skip and then blame the model for.
The five levels of AI capabilityWhat the engagement contains
The actual work.
Manufacturing Quality
Quality operating systems with real KPIs: warranty analysis binned by impact, DFMEA and PFMEA run against actual failure data rather than an assumed severity, and a feedback path that turns field failures into design changes instead of into reports.
Supply Chain
Supplier quality and performance where it is measurable — early warning on supplier software quality, recovery of what has been overpaid, and connecting supplier data to the design decisions that depend on it.
Systems Engineering
Requirements you can follow through to the test that proves them, across mechanical, electrical and software. This is the discipline ASPICE and ISO 26262 audit for, and the reason regulatory work is either tractable or a permanent tax.
Who does the work
The people who have already done this.
Envorso staffs engagements with operators who have held the job you are hiring for. Not analysts who have studied it, and not a junior team with a template.
Stuart Taylor
Chief Executive Officer
Deputy CEO for electronics and software at VinFast; 17 years at Ford
Steve Tengler
Chief Growth Officer
30+ years in automotive product development
Florian Frischmuth
Senior Vice President, Digital Engineering
Executive Director, Vehicle Controls, Ford
Sakis Kitsopanidis
Partner, CIO Practice
28 years at Ford and Ford Credit, including Interim CIO
Michael Dennis
Partner, Enterprise Architecture
30+ years in enterprise software — Disney, Microsoft, ExxonMobil; three patents
Keshav Puttaswamy
Senior Vice President, Product Management
25+ years — Microsoft, Atlassian, Meta
J. Caldwell
Atlassian Solutions Architect and Practice Lead
20+ years in enterprise IT operations — Disney, Expedia, AT&T Wireless; Atlassian-accredited
John McCauley
Director, Portfolio Management
16+ years in portfolio management — Deloitte, UMT Consulting Group
Proof
Where we have done this before.
3 engagements where this work was the difference, with what changed and by how much.
Industrials
−75%Building a Data-Driven Operating System
Reducing warranty claims by 75%
Warranty failure rates approached 100% during the coverage period. Key dealers were leaving, market confidence was eroding, and there was no instrumentation to explain any of it — no defined KPIs, no warranty analysis process, and therefore no way to tell which failure was worth fixing first.
A motorized equipment manufacturerAutomotive
Powering Up
A quality battery reboot
Battery assembly lines and prototype builds were not meeting the quality standard required to scale, against tight timelines and rising complexity. Without a quality operating system, each defect was investigated as an incident rather than as a signal.
A rapidly growing EV startupAutomotive
6 monthsCertifiably Ready
Compliance that scales
EU regulation UNECE R156 requires a certified Software Update Management System. Without it, the company could not continue selling vehicles in Europe.
A global automotive manufacturerHow it starts
Evaluate → Improve → Confirm. We drive.
Three steps, in order, every time — and an operator of ours driving all three. The first is deliberately small and deliberately purchasable, because nobody should commit to a transformation program before anyone has established what is actually wrong.
Two hours to find out whether we recognise your problem.
No deck, no obligation. We listen, we tell you whether we have seen this before, and we say what we think it would take. If a Jump Start is the right next step we will say so — and if it is not, we will say that too.