Quality Management in Production

Creating structure – We support the development of comprehensive quality management frameworks as a strategic foundation. This includes defining a shared understanding of quality, establishing defect specifications, and forming a dedicated defect analysis team.

Why it matters: Without a shared understanding of quality, clearly assigned responsibilities, and documented processes, there is no reliable basis for any further improvement initiatives.

Your benefits at a glance:

• Development of an ISO 9001-compliant quality management system
• Implementation of an objective defect catalog
• Structured documentation of key processes
• Preparation for additional certifications (e.g., ISO 14001)

The challenge

A mid-sized mechanical engineering company lacked an established quality management system. There were no documented processes, no clearly assigned responsibilities, and no preparation for ISO 9001 certification. As a result, customer requirements could only be addressed reactively, leading to growing dissatisfaction.

Our solution

We guided the company through the structured development of a quality management system. Through a series of workshops, we identified over 100 relevant processes, prioritized them based on impact, and documented more than 70 of them using SharePoint. A defect analysis team was established, and a clear, organization-wide quality standard was defined.

The result

• ISO 9001 certification achieved within six months
• 25 percent reduction in internal rework
• Foundation laid for subsequent ISO 14001 certification
• Consistent understanding of quality across the organization

Measure. Detect. Act. – We design and implement both automated and manual quality assurance systems, including the development of predictive quality models tailored to your needs.

Why it matters: Only those who systematically collect and analyze relevant quality data can make informed decisions and act proactively.

Your benefits at a glance:

• Structured quality data models for more efficient data collection
• Reduced inspection workload through automated detection
• Early error detection with predictive quality techniques

The challenge

A high-volume manufacturer serving international customers faced major issues during final inspection. Manual visual checks were labor-intensive, prone to error, and difficult to standardize due to varying customer requirements (e.g., different defect types and tolerance levels).

Our solution

We developed a software tool that uses a configurable defect catalog to automate customer-specific inspection strategies. Defect types were clearly defined, systematically categorized, and integrated into the software as parameters. The tool dynamically adjusts inspection modes based on customer profiles – while minimizing manual intervention.

The result

• Inspection time reduced by up to 70 percent
• 40 percent improvement in detection accuracy
• Standardized inspection processes despite customer-specific needs
• Fewer complaints and higher customer satisfaction

Creating transparency through structured systems – We implement standardized systems for capturing, storing, and visualizing quality data.

Why it matters: Reliable management decisions depend on solid data. Complete documentation also supports audits and increases internal transparency.

Your benefits at a glance:

• Standardized defect coding and centralized database setup
• Visualization of quality trends and performance over time
• Full traceability and ensured compliance

The challenge

A company had no structured process for capturing or analyzing quality data. Defects occurred regularly but weren’t systematically documented. As a result, improvement decisions were made on instinct, and audit readiness was poor.

Our solution

We introduced standardized defect coding and built a centralized quality database to store and analyze all detected defects. A dashboard was implemented to visualize and analyze data in real time. Key quality parameters were also statistically tracked.

The result

• 100 percent traceability of all quality issues
• Data-driven decision-making at the management level
• Successful audit readiness
• Identification of systemic weak points across the value chain

Understanding the root causes – We offer data-driven root cause analysis using statistical methods, Six Sigma tools, and machine data analytics.

Why it matters: Sustainable quality improvements are only possible when the root causes of defects are fully understood and systematically eliminated.

Your benefits at a glance

• Identification of process instabilities
• Reduction of energy and resource costs
• Improved basis for production decisions and adjustments

The challenge: A manufacturer in an energy-intensive industry (e.g., chemicals) was facing high scrap rates with unknown causes. At the same time, energy costs were rising, especially due to rework and unplanned machine downtimes.

Our solution

Using data-driven methods such as cluster analysis and time-series analytics, we analyzed large volumes of machine data. This revealed several outliers and unexpected machine events linked to defective batches. In parallel, we analyzed energy consumption patterns for correlations with process deviations.

The result

• Annual savings of over one million euros through reduced scrap and process optimization
• Significant reduction in energy consumption per unit produced
• Improved process stability and planning reliability
• A data-based understanding of quality and cost drivers

Sustainable optimization through structured processes – We help implement structured improvement systems (e.g., FRACA, CIP) and lean methods to prevent defects and increase efficiency.

Why it matters: Quality is not a fixed state – it’s a process that requires continuous improvement

Your benefits at a glance

• Systematic root cause elimination
• Optimized ramp-up and new production processes
• Increased yield and faster time-to-market

The challenge

An electronics manufacturer was in the ramp-up phase of a new product, achieving only 30 percent initial yield. Although many issues were known, there was no structured approach to resolve them, threatening a delay in market launch.

Our solution

We introduced a structured FRACA system (Failure Reporting, Analysis, and Corrective Action). Interdisciplinary teams systematically documented, prioritized, and resolved defects. We also facilitated hands-on improvement processes through regular workshops and reviews.

The result

• Yield increased from 30 percent to 87 percent within 5 months
• On-time transition to full-scale production
• Fewer customer complaints and reduced rework
• A sustainable, company-wide culture of problem solving