The Rcalls blog
Perspectives on automotive quality, warranty management, extended warranty, and the insurtech enabling it all — from the team building it.
Why 8D analysis still matters — and why most teams are doing it wrong
The 8D method has been around for decades, but disconnected data means teams spend more time filling in reports than fixing the actual root cause.
Recent articles
Subscribe to updates →Traceability in Automotive Manufacturing
Defects in manufacturing rarely occur in isolation. In most cases, they develop within specific batches, suppliers, or process steps before spreading across products and reaching customers.
From spreadsheets to real-time: how manufacturers are modernising BoM traceability
Most automotive manufacturers still track component traceability in spreadsheets. Here's what the transition to real-time BoM data actually looks like in practice.
The Limits of Spreadsheets in Quality Risk Management
Quality issues rarely appear without warning. In most cases, defects, supplier problems, and process deviations develop gradually before they escalate into larger operational failures or…
How Quality Data Can Improve Insurance Risk Evaluation
Product recalls are one of the most complex risks manufacturers face, involving safety concerns, regulatory scrutiny, and significant financial impact. According to the National Highway…
The extended warranty opportunity: why manufacturers are leaving revenue on the table
Extended warranty is a multi-billion dollar market that manufacturers are ceding to third parties. The data to compete is already in their systems.
Stellantis Recalls 700,000 Hybrid Vehicles Over Fire Risk
Stellantis has announced a global recall of up to 700,000 hybrid vehicles due to a potential fire risk linked to component interaction within the powertrain system. According to Reuters…
How insurers can use manufacturer quality data to price extended warranty accurately
Insurers have long priced extended warranty on historical averages. Real-time manufacturer data changes the equation — and the loss ratio.
Straight-through processing for warranty claims: what it takes to hit 95%+ automation
Reaching high straight-through processing rates isn't just about software — it's about data quality, claim rules, and the right escalation logic.
Integrating ERP and MES data into a unified quality platform: lessons from the field
Connecting SAP, Oracle, and Siemens systems to a live quality layer is harder than it looks. Here's what we've learned doing it across a dozen manufacturers.
How a Tier 1 automotive supplier cut warranty costs by 34% in under 12 months
A European powertrain manufacturer connected their BoM and claims data on Rcalls. Within a year, recurring defects dropped by 60% and warranty costs followed.
Specialty Vehicle Recalls
Product recalls are rising concerns across the automotive industry, but not every vehicle type carries the same operational risk. In The Rising Wave of EV Recall, Rcalls highlighted how EV…
From 6-week claim cycles to 4-hour resolution: an EV manufacturer's warranty transformation
An electric vehicle manufacturer used Rcalls's automated triage to process 97% of warranty claims without human intervention — dramatically improving customer satisfaction.
Top Recalled Components
Over the last few years, the automotive industry has undergone one of the most significant transformations in its history. Electrification, digitalization, and increasingly complex supply…
The Rising Wave of EV Recall
As electric vehicles rapidly enter the mainstream, their technological complexity, especially around high-voltage batteries, is reshaping the landscape of automotive recalls.
Jeep 4xe recall: Estimating the Real Cost of a Product Recall Campaign
On November 4th, Stellantis announced the recall of more than 375,000 Jeep Wrangler and Grand Cherokee 4xe plug-in hybrids around the World.
Latest Loss Ratio in Product Recall Insurance
The global product-recall landscape has changed dramatically. From contaminated food batches to defective automotive parts, recalls are more frequent, more expensive, and more complex than…
Understanding Loss Ratios in Product Recall Insurance
When insurers evaluate the performance of any insurance line, one metric quietly shapes everything — the loss ratio. It tells us how much of the collected premium is paid back in claims…
Supply Chain Transparency: Preventing Manufacturing Recalls
In today’s interconnected manufacturing world, one weak link in the supply chain can trigger a costly product recall. From automotive parts to electronics, a single missing piece of…
Why SMEs Are the Hidden Frontier of Recall Risk, And How Insurers Can Tap into It
When people think of product recalls, they often imagine global manufacturers or consumer-electronics giants. Yet, behind every large recall lies a chain of small and medium-sized suppliers…
5 Ways Brokers Add Value Beyond Price in Recall Insurance
The recall insurance landscape is more competitive than ever. Manufacturers are comparing quotes, brokers are pressured to cut premiums, and insurers are fighting for renewals.
How Brokers and Insurers Can Win More Product Liability & Recall Insurance tenders
Across Europe, SMEs remain the most underinsured segment when it comes to product liability – even though they design, produce, or assemble goods that can trigger claims or recalls.
The Best Tools to Prevent Product Recall Claims
Product recalls remain one of the costliest and most complex risks for both insurers and manufacturers. A single defective batch can trigger millions in claims, regulatory action, and…
Rcalls joins the London Business School Incubator 2025/2026 Cohort
Rcalls is proud to announce its selection as part of the London Business School (LBS) Incubator 2025/2026 cohort.
Rcalls Concludes RESTART Program
Earlier this year, Rcalls joined the RESTART Mentorship and Entrepreneurship Program promoted by Politecnico di Torino and Plug and Play Tech Center under Spoke 4 – Programmable Networks…
The cost of the product recall insurance in the automotive industry
Product recalls are more than a technical issue. In the automotive industry, they translate into high financial costs, reputational damage, and significant insurance implications. As…
How to stay competitive in the product recall insurance market?
In Q1 2025, European product recalls reached 3,925 events across five key industries, the highest quarterly total in 11 years, according to Sedgwick’s latest European Product Safety and…
The Rising Threat of High-Voltage Cable Theft from EV Charging Stations in Europe
As the adoption of electric vehicles (EVs) accelerates across Europe, a surprising and costly challenge has emerged: the theft of high-voltage charging cables from EV charging stations…
Tier-1 Automotive supplier reducing the yearly cost of non-conformance claims from OEMs
In today’s manufacturing landscape—where quality, traceability, and risk exposure are under constant scrutiny—a Tier-1 European automotive supplier was facing growing challenges in managing…
Rcalls to Join the Politecnico di Torino and Plug and Play Mentorship Program (RESTART) to Drive Innovation in Digital Transition Technologies
Product recalls are on the rise, especially in Europe. Supply chain disruptions, more stringent requirements and consumer demands have led to more defective products. Large businesses…
Rcalls enters the I3P incubator program
Product recalls are on the rise, especially in Europe. Supply chain disruptions, more stringent requirements and consumer demands have led to more defective products. Large businesses…