A successful supplier of mechatronic systems for aircraft had run into a serious bottleneck with high backlogs due to increases in demand and quality problems. The interim manager was commissioned as project manager to solve the production problems at the German plant.
Inadequate quality control loops identified as the main cause
In the analysis, the interim manager was able to quickly identify a number of causes together with the specialist departments. Firstly, the testing technology was not up to date. The manual data collection and logging was very bloated and lacked transparency. In addition, the quality control loops were barely effective. All of this led to high error costs and was the main cause of the bottlenecks. Based on these findings, the interim manager developed several measures with high potential for improvement.
Testing technology modernized, optimized and automated
First, the interim manager focused on the testing technology. He upgraded the functional testing of the products with computer-aided testing systems that enable a largely automated testing process. He also optimized the ergonomics of the test benches according to REFA methods. This also enabled him to drastically reduce testing and set-up times.
The interim manager installed a flexible database for the measurement data, from which test reports are now generated fully automatically. The quality data is immediately available and enables an immediate response to deviations and automatic evaluations.
Methods of modern quality management introduced
In order to improve the effectiveness of the quality control loops, the interim manager also introduced methods of modern quality management. For example, all key quality information is now visualized promptly and is always part of regular team meetings.
Training for error culture and problem-solving techniques such as 5W and 8D
At the same time, the interim manager trained employees in problem-solving techniques such as 5W and 8D. This made it easier to quickly initiate the right corrective measures. The interim manager attached great importance to establishing a constructive error culture in the teams. Employees now discuss quality issues and corrections in lessons learned workshops. If errors occur, they are escalated immediately and immediate measures are defined.
Quick Response Quality Control strengthens identification and effectiveness
With the new quality control loops and the constructive error culture, the teams can respond to errors much more quickly and in a more targeted manner. Sensitivity to errors and the personal responsibility of employees is strengthened by the Quick Response Quality Control that has now been introduced. Another positive side effect is that teamwork, transparency and measurable successes have increased employee identification and motivation.
Productivity increased by 300 percent - costs reduced by 1 million euros
The interim manager's package of measures enabled backlogs to be quickly reduced and delivery reliability to be restored. The fast control loops have significantly reduced the error rate. Parallelization of the functional tests increased productivity by 300 percent. The expenses for set-up times in the test bench (minus 80 percent) and test documentation (minus 72 percent) were significantly reduced. Overall, the savings amount to almost 1 million euros.
The project in a nutshell:
- Increased quality and productivity in aviation companies
- Inadequate quality control loops identified as a major cause
- Testing technology and test data modernized, automated and optimized
- Methods of modern quality management introduced
- Quick Response Quality Control strengthens identification and effectiveness
- Internal and external quality significantly improved
- Productivity increased by 300 percent - costs reduced by 1 million euros
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