Real-World Example
Modern Problem Management for Processes
If we are to succeed in the long term at preventing product issues not only 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 customers 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 been the panacea for reducing warranty and guarantee costs (field issues and recalls) for years. 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 errors). The root causes of these product issues, however, lie in the lack of optimization of the processes that could prevent defects 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 Description
- 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).
- Design and implementation of the corresponding toolset for the proposed process and method based on Microsoft Excel (VBA).
- Implementation of specific reporting and analysis tools to manage the partners involved at process interfaces and to identify cross-functional areas requiring action (template).
KBC Approach
Based on specific technical product issues (e.g., field issues or recalls), the root cause analysis methodology allows for the rapid, structured, and methodical 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.
