Rolls Royce Motor Cars Limited

Quality Specialist - Interior Trim

Working as a Quality Specialist in the Interior Trim department of Rolls-Royce Motor Cars Limited provided me with a unique opportunity to operate at the intersection of luxury craftsmanship, engineering excellence, and cutting-edge quality systems. This role was both technically challenging and professionally fulfilling, as it required a seamless balance of mechanical engineering principles, adherence to global quality standards, and the application of data-driven methodologies to ensure flawless execution in a high-stakes production environment.

Scope of Work: Interior Trim Quality

The Interior Trim of a Rolls-Royce is not just a product—it is a defining feature of the brand's legacy. From bespoke leather stitching to handcrafted veneers and precision-assembled components, every detail is scrutinised for perfection. My role was embedded within this environment, supporting the entire quality lifecycle from supplier part approval to final fit and finish on the assembly line.

I was responsible for ensuring that all interior components met or exceeded the required specifications, functional performance, and aesthetic quality standards. My work extended from problem-solving on the production floor to strategic data analysis and process improvement initiatives.

Technical Standards and Frameworks

In a luxury automotive environment, quality is governed not only by customer expectations but also by stringent industry standards. I ensured compliance with:

• ISO 9001:2015 Quality Management Systems

• IATF 16949 Automotive Quality Management Systems

• VDA 6.3 Process Audit (particularly relevant to supplier audits)

• GD&T (Geometric Dimensioning and Tolerancing) for precision assembly and component verification

• PPAP (Production Part Approval Process)  applied to key interior components and leather parts

• FMEA (Failure Mode and Effects Analysis) – to assess and mitigate potential design and process risks

  
  

I actively participated in APQP (Advanced Product Quality Planning) meetings for new model introductions and coordinated closely with design, manufacturing, and supplier quality teams to align on specifications and process capabilities.

Problem Solving and Issue Resolution

One of my core responsibilities was to lead root cause investigations and support real-time issue resolution. This involved applying structured problem-solving techniques such as:

• 8D (Eight Disciplines)

• 5 Whys

• Ishikawa Diagrams (Fishbone Analysis)

  
  

I handled Non-Conformance Reports (NCRs) across multiple build stages, identified systemic root causes, and collaborated with engineering teams and suppliers to implement Corrective and Preventive Actions (CAPAs).

In one case, a recurring stitch line inconsistency on door panels was traced back to a combination of material stretch variation and operator handling. I led a multi-departmental initiative that involved revising the standard work instructions, revalidating the material batch specifications, and deploying a training module for trim operators. This led to a 28% reduction in rework over two production cycles.

Supplier Development and Component Validation

Working closely with Tier 1 and Tier 2 suppliers was essential, especially given the bespoke nature of Rolls-Royce interiors. I conducted:

• Supplier audits and readiness assessments

• PPAP reviews and approvals

• Incoming part inspections

• First Article Inspection (FAI) validations

• Dimensional and visual inspections using CMM and handheld gauges

In collaboration with the supplier quality team, I helped develop control plans for critical components such as veneered fascias, leather-wrapped consoles, and ambient lighting elements, ensuring alignment with visual acceptance criteria and tolerances.

I also contributed to material validation and testing, particularly for new colour and grain combinations introduced as part of customer-specific bespoke orders.

Data Engineering and Quality Analytics

What set me apart in this role was my ability to merge engineering knowledge with data analysis and business intelligence tools. I was instrumental in digitising certain quality reporting processes and developing automated dashboards using:

• Power BI for visualising defect trends, rework rates, and supplier quality performance

• SQL for querying large datasets from the quality management system (TrackWise and SAP)

• Excel (Advanced functions and PivotTables) for day-to-day reporting and ad hoc analysis

• Python (Basic level) to automate repetitive data tasks and prepare datasets for reporting

  
  

These tools helped identify patterns that manual inspection reports often missed. For instance, a spike in reject rates during colder months was analysed using time-series defect data, which revealed that ambient temperature variations were impacting the adhesive curing time of leather-wrapped panels. This insight led to adjustments in process parameters and climate control settings in the trim shop.

New Model Introduction (NMI) and Launch Support

Supporting New Model Introductions (NMI) was a key part of my role. I was deeply involved in the early builds, validation stages, and launch readiness activities, which included:

• Conducting line readiness reviews

• Preparing visual quality standard documents

• Supporting early defect containment actions

• Participating in design reviews for manufacturability

• Implementing layered process audits (LPAs) to ensure build consistency

For the launch of a new bespoke model, I supported the validation of a new two-tone leather trim design, where slight misalignments were extremely visible due to the high-contrast colour combination. I worked with both the design and production teams to refine stitching templates and updated the standard inspection criteria accordingly.

Cross-Functional Collaboration and Training

Quality in interior trim is a cross-functional responsibility, and I regularly collaborated with:

• Design & Engineering - for alignment on specifications and tolerances

• Production & Operators - for real-time issue resolution

• Logistics - for packaging and handling quality

• Supplier Quality - for external component validation and escalation

• Customer Quality - for feedback loop and warranty issue analysis

I also conducted training sessions for operators and inspectors, particularly focused on visual quality standards, defect categorisation, and standardised defect tagging processes.

Results and Impact

My work contributed directly to:

• A 30% reduction in rework hours related to interior trim over a 6-month period

• An improvement in First-Time Quality (FTQ) scores for trim assembly

• Enhanced audit readiness and zero major non-conformities in internal audits

• Reduced response time for NCR closures through improved digital workflows

  
  

Conclusion

This role allowed me to blend precision engineering, regulatory compliance, and data analytics in one of the most demanding and prestigious environments in the automotive world. It taught me that delivering world-class quality requires more than meeting specifications, it demands a mindset of continuous improvement, deep technical knowledge, and seamless collaboration between people and systems.

Through my experience at Rolls-Royce Motor Cars, I’ve gained a profound understanding of how quality engineering is both a science and an art, especially when excellence is not just a goal, but a promise.