Real-World Example
Sustainable Error Correction
To achieve the quality goals in the production process of a leading automotive OEM, we launched a cross-plant zero-defect program.
Background
In today’s economic climate, reliability management in the automotive industry faces a wide range of challenges. Rising demands on the safety and reliability of end products stem from increasing customer expectations. Complex processes, a wide variety of products, and shorter production lead times are therefore also key factors influencing product quality during production. The automotive industry faces the challenge of reducing high quality costs while still meeting quality targets.
Specific Task Description
- Reducing High Quality Costs in Production
- Implement the strategic directions that have already been decided upon and harmonize them across all plants
- Develop specific optimization projects in terms of both content and business management
- Develop a governance model for implementing cross-plant standards
KBC Approach
When establishing a zero-defect initiative in the production area, we were able to support our client with our many years of experience in launching large-scale optimization initiatives. We served as the right-hand partner to our client’s program management team and, as part of the project team, jointly guided the substantive and business-related direction of the subprojects across all plants. Using a value chain-based approach to calculate the potential savings from warranty and guarantee claims, we were able to quickly assess the initial financial benefits resulting from the optimization measures implemented. This ensured active support from the individual plants and production management in launching the subprojects right from the start.
