Avoid Errors, Reduce Quality Costs - KBC
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Real-World Example

Avoid Errors, Reduce Quality Costs

We optimized the production processes of a leading automotive OEM with the goal of achieving “zero defects.”

Background

Manufacturers and OEMs continue to focus more on reactive measures after errors occur than on preventive ones—even though prevention and testing would reduce the subsequent costs of error correction. Process control is good, but process stability is still insufficient. Key performance indicators are in place, but the early detection and prevention of risks are not guaranteed. The interpretation of key performance indicators—including the derivation of appropriate actions—falls short of what is possible. At the same time, the speed of defect resolution is playing an increasingly important role. A shift in mindset is therefore needed: a focus on prevention rather than reaction. Action must be taken before defects reach the customer.

Specific Task Description

  • Increasing the Effectiveness of the Zero-Defect Program Within the Organization
  • Resolving Conflicts When Prioritizing Program vs. Line Functions
  • Increase the maturity level of the pilot initiatives for the rollout
  • Establish a clear, consistent reporting structure
  • Simplify and standardize the process for applying for funding
  • Fuel the generation of ideas for error prevention

KBC Approach

KBC brings precision and pragmatism to pinpointing the root causes of errors in business processes. We are able to identify the relevant areas for optimization using fewer key metrics and take clear ownership of them. Our proven methodology for business case evaluation enabled us to prioritize measures effectively, thereby enhancing our client’s reputation among its interface partners and the executive board.

Portrait photo of Bene Budde, partner at Kemény Boehme Consultants (KBC). A man with short, dark brown hair and distinctive black rectangular glasses smiles warmly at the camera. He is wearing a dark blue jacket over a white shirt without a tie, along with dark jeans and a black leather belt; both hands are casually in his pants pockets, and he has a relaxed and approachable demeanor.
Portrait photo of Bene Budde, partner at Kemény Boehme Consultants (KBC). A man with short, dark brown hair and distinctive black rectangular glasses smiles warmly at the camera. He is wearing a dark blue jacket over a white shirt without a tie, along with dark jeans and a black leather belt; both hands are casually in his pants pockets, and he has a relaxed and approachable demeanor.
Benedikt Budde
Partners

Impact Achieved

KBC helps you establish robust processes, monitor them, and continuously improve them. With our support, you’ll complete the process—from project assignment to implementation—twice as fast as you would on your own. To do this, we draw on our many years of experience in the automotive industry as well as proven tools and methods. Working together with you, we can ensure that mistakes aren’t repeated and that the number of errors is reduced.