Quality & Reliability Audits
Quality defects drive high after-sales costs and damage brand reputation. FUTUREMOTION helps prevent downstream failures before they happen.
Drawing on years of hands-on experience with industry leaders, FUTUREMOTION delivers structured quality and reliability audits across the full product lifecycle, from design validation at your suppliers, through process verification on the production line, to root-cause analysis after field claims.
Each engagement is built around proven quality tools (PPAP, FMEA, 8D, RCA) and adapted to the specific component or assembly involved, whether it’s a motor, controller, display, battery, or frame.
Design & Development Audit (PPAP)
We audit your suppliers’ design and development process against PPAP (Production Part Approval Process) requirements to ensure quality is engineered in from the earliest stages, not retrofitted on the production line. The scope covers design records and engineering change control, DFMEA, validation and reliability test plans, control plans and PFMEA, measurement system analysis (MSA), and qualification of the supplier’s internal processes.
Each audit targets critical parts you define (motor, controller, display, battery, frame) and follows a structured methodology: an audit template tailored to the component’s technical and regulatory profile.
On-Site Test & Validation Verification
We verify, at the supplier’s facility, that the test and validation plan for each critical component is correctly defined, executed, and produces reliable results.
The verification covers test plan completeness against applicable standards (EN 15194 for EPACs, IEC 62133 and UN 38.3 for batteries, EMC, IP rating, durability cycles), equipment calibration, sample traceability, and the failure handling protocol.
Scope is calibrated to the part: around 40 tests for a motor (torque, efficiency, thermal, EMC, endurance) versus around 10 for a frame (fatigue, impact, corrosion).
Production Process Verification (FMEA / Control Plan) & Inline Inspection
We audit the production process against the supplier’s FMEA and Control Plan to confirm that quality controls are in place and effective, covering SMT/DIP PCBA, pre-assembly, main assembly, and IQC/IPQC/OQC stages for a motor, or main production and inspection for a frame.
We then extend this work onto the line itself during pilot runs and early mass production, monitoring First Pass Yield and failure rates to catch and resolve critical issues before volumes scale up.
RCA & Corrective Action Verification (8D)
Following a quality claim, we verify that the supplier’s root cause analysis is conducted with proper quality tools (5 Why, Ishikawa, Pareto, FTA) rather than guesswork, confirm the root cause verification process, and check that corrective actions are effectively implemented and sustained. The engagement is documented in an 8D format report and scaled to the complexity of the issue.
