Automotive · engineering, quality and cost
The same defect, two vehicle programs later.
Each new program repeats issues the last one already fixed. Synsa remembers every closed defect and recognises it under a new part number or a new team's words.
What your teams live with
- A field issue turns out to be an old one under a new part number.
- 8D reports get closed and filed. The lesson stays in the PDF.
- Cost-down ideas get evaluated, dropped and forgotten. Two years later, someone proposes them again.
Two records, one shape
Illustrative exampleSynsa brings back the 2023 fix and the engineer who confirmed it.
Cost engineering
Every cost-down idea, ready for the next RFQ.
Synsa brings back the 2023 evaluation and why it was dropped, so the new study starts from the earlier numbers.
Where Synsa reads from
- Jira and defect trackers
- Polarion
- Codebeamer
- 8D reports
- FMEAs
- Test reports (TestRail)
- Warranty claims
- Should-cost models
- Teardown and benchmark reports
- RFQ and quote history
What you measure
- Time to resolve
- Repeat issues per program
- Late changes before SOP
- Warranty cost
- Savings realised per idea
Estimate your return
What repeat defects cost your engineers today.
Estimate only, using your numbers. Assumes a case matched to an earlier one is resolved in half the time, and 140 working hours per analyst per month. In the first week we measure your real figures and agree the baseline with you.
From pilot to payback
Six weeks on your hardware. Then it keeps running.
- Week 1
Connect
Read-only links to your defect tracker and 8D reports, on your hardware. Baseline KPIs agreed and signed.
- Weeks 2–3
Learn
Closed defects become Traces. Synsa finds the patterns that repeat across programs. Your engineers confirm them.
- Weeks 4–6
Run
Every new defect is checked against confirmed patterns. Engineers see the earlier case and the fix that worked.
- Week 6
Prove
Return-on-investment readout against the baseline, signed by both sides. The memory keeps running.
Context: in the Synsa recurrence study (2025), 65.5% of 1,618 real engineering issues from two vehicle programs had happened before, in different words.
Questions we hear
- How does Synsa find a defect that was described in different words?
- Synsa stores each closed defect as a Trace built around its shape: what happened, under which conditions and what fixed it. A new ticket is matched on that shape, so a renamed part or another team’s wording still finds the earlier case.
- Which automotive engineering systems can Synsa read?
- Defect trackers such as Jira, Polarion and Codebeamer, 8D reports, FMEAs, test reports from TestRail, warranty claims, should-cost models, teardown and benchmark reports, and RFQ and quote history. Access is read-only.
- Can Synsa help cost engineering as well as quality?
- Yes. Every cost-down idea is kept with the reason it was approved or dropped, so the next RFQ starts from the earlier evaluations.
- Does our engineering data leave the company?
- No. Synsa runs on your hardware, without internet, and reads your systems read-only. Sensitive data is masked on arrival.
- What does the six-week pilot deliver?
- A running memory of your confirmed defects, the patterns that repeat most with their cost, and a return-on-investment readout against KPIs agreed in week one. It runs at a fixed fee.
- What is a Trace?
- A Trace is one thing your company has learned: the shape of a problem, its facts, its fix and who confirmed it. Synsa uses Traces to recognise a problem when it comes back.