The interim manager was hired by a southern German automotive supplier from the SME sector that was experiencing enormous resource shortfalls in quality assurance. This resulted in poor delivery performance for all new projects. The situation was critical for the customer, but also for the profitable processing of new orders. The management therefore decided to entrust the interim manager with the sampling of the EMPB (initial sample test report) and to use him as support in the management of new projects.
Sampling process reactivated and processes reintegrated into the project
After a very brief assessment of the current situation, the interim manager identified the current causes. Due to the increase in projects and the departure of employees, there was a lack of personnel resources. There was also a knowledge gap in the methods for sampling inspections and project management.
Process for PPF procedures restructured in accordance with VDA Volume 2 and PPAP
In the first sub-project, the interim manager developed a small package of measures to close the gaps. In particular, he revised the quality assurance processes. He described the new processes in a procedural instruction. The introduction of the automotive core tools (initial sample test report, or EMPB for short, in accordance with VDA Volume 2 and PPAP) also made a significant contribution to improved quality control.
In parallel, the interim manager set about working through the open sampling inspections and submitting initial sample test reports to the customers. At the same time, the material database was maintained for the EMPBs and the IMDS entries (IMDS: International Material Data System for recording the substances and components of products in the automotive industry) were created. Another important and efficient measure was the reduction and elimination of the time-consuming paper documentation. A scanner was purchased and the archiving of all documents and test reports was implemented electronically.
EMPBs and IMDS entries processed correctly and backlogs reduced
The external interim manager was able to fundamentally optimize the sampling inspection process and the interface to project management. The backlog of open samples and missing IMDS entries was reduced and the customer-specific requirements for sampling were implemented. The VDA Volume 2 regulations and the PPAP manual were integrated and the other internal QA employees were trained. The new process flow in quality assurance and those responsible have been effectively restructured.
After the backlogs were reduced, the project calmed down and on-time delivery was ensured again.
