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Practical example

Avoid errors, reduce quality costs

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

Background

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

Specific task

  • Increasing the effectiveness of the zero-defect program within the organization
  • Resolving Conflicts Between Program and Line Functions
  • Increase the maturity level of the pilot initiatives for rollout
  • Establish a clear, consistent reporting structure
  • Simplify and standardize the process for applying for funding
  • Fostering ideas for error prevention

KBC's Approach

KBC brings precision and pragmatism to the process of identifying the root causes of errors. We are able to pinpoint 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 the right measures, thereby enhancing our client’s standing with their partners and the executive board.

A man with short brown hair and dark blue eyes, wearing glasses and smiling; he is wearing a white shirt and a dark blue suit and is standing with both hands in his pants pockets
A man with short brown hair and dark blue eyes, wearing glasses and smiling; he is wearing a white shirt and a dark blue suit and is standing with both hands in his pants pockets
Benedikt Budde
Partner

Impact achieved

KBC helps you establish robust processes, monitor them, and continuously improve them. With our support, you can move from project assignment to implementation twice as fast as you could 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 with you, we can ensure that mistakes aren’t repeated and that the number of errors is reduced.