Resolving Manufacturing Crisis Using Quality Control to Reduce Costs by 29%

At a well-known international electrical connector manufacturing company, MetaExpert Donald found himself facing a daunting challenge. He was tasked with achieving cost reductions in a product that had been on the market for 30 years, and in the process, he encountered a sudden and unprecedented crisis. The product, renowned for its quality and safety, began to fail quality control tests just two weeks after his arrival. The absence of process documentation and unchecked cost-cutting measures led to alarming field failures, endangering public safety and corporate reputation.

After remedying the issue, MetaExpert Donald achieved:

• Reduced Variation by 39%. The tensile strength variation was minimized, resulting in a more consistent and reliable product.
• A 29% Cost Reduction. Cost reduction was achieved with a clearer understanding of process variables and controlled changes.

Skills Needed

• Process Engineering Expertise
• Statistical Analysis
• Six Sigma Principles
• Process Mapping
• Ishikawa Diagram
• Failure Mode and Effects Analysis (FMEA)
• Design of Experiments (DOE)

Contract Length

6 Months