Practical example
Modern Problem Management for Processes
To successfully prevent product issues in the long term—not just reactively but also proactively—we must systematically optimize the weak points in both value-added and non-value-added processes. Drawing on our many years of experience in process optimization, we work with our clients to design the relevant processes, methods, and tools, and implement the results all the way through to handover to the production line.
Background
For many companies, reactive problem management has long been seen as a panacea for reducing warranty and guarantee costs (field issues and recalls). However, product issues are not resolved in the long term—and especially not across product generations—because value-adding and non-value-adding processes repeatedly cause the same errors (e.g., recurring defects). The root causes of product issues, however, lie in the lack of optimization of processes that could prevent errors proactively. Optimizing inadequate procedures and establishing methods for root cause and process analysis are therefore the key challenges in shifting from a reactive to a preventive approach.
Specific task
- Design and implementation of a company-wide process and methodology for root cause analysis (generic) of process issues when product problems arise.
- Development of management and analysis processes, including a suite of tools (Excel).
- Development and implementation of the corresponding toolset for the designed process and methodology based on Microsoft Excel (VBA).
- Implementation of specific reporting and analysis tools to manage the partners involved in the process interfaces and identify cross-functional areas requiring action (templates).
KBC's Approach
Based on specific technical product issues (e.g., field issues or recalls), the root cause analysis methodology allows for the rapid, structured, and systematic identification of the corresponding process weaknesses using the root cause tree. Targeted process improvement measures are derived from the identified weaknesses, thereby resolving the product issues in a sustainable manner.
