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Tata Strategic used four broad levers to meet the client’s objectives. Capability up-gradation was used to build expertise in critical areas by adding qualified manpower; Accountability for quality by elimination of most of the inspection activity by assigning accountability for the quality of machining, assembly and manufacturing processes to the manufacturing function; new role definition for QA by redefining roles and responsibilities of the quality assurance function so that its focus is on long-term product and process improvement; manpower rationalization by reducing manpower through technology up-gradation, zero basing, supplier quality improvement and outsourcing.

It was assessed that the client could achieve a 28 per cent manpower reduction over two years if the recommendations were implemented. The client has restructured the quality assurance function in line with the recommendations and also implemented an 8 per cent manpower reduction in the first year itself.