Process Improvement
Defect Reduction & Statistical Process Control (SPC)
High defect rate on a critical assembly line drove rework and customer complaints. Root cause analysis (8D, 5-Why), SPC limits, real-time Power BI dashboards, and operator training on out-of-control response.
Outcomes
- ~40% defect reduction
- Faster containment via automated alerts
- Audit-ready SPC documentation
SPC
8D
Root Cause
Power BI
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Analytics & Dashboards
Unified Quality Dashboards
Quality and production data lived in spreadsheets and legacy systems. Built a single source of truth with SQL ETL and Power BI dashboards for incoming, in-process, and customer quality.
Outcomes
- ~60% less time on manual reporting
- Same-day visibility for management
- Drill-down from plant to part level
Power BI
SQL
DAX
ETL
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Quality Systems
CAPA & Audit Readiness
CAPA and nonconformance records were fragmented; external audits required last-minute scrambling. Standardized CAPA workflow and central audit pack with traceability to ISO 9001.
Outcomes
- Zero major findings in follow-up audit
- Faster CAPA closure with clear ownership
- Supplier audit scorecards in one place
CAPA
ISO 9001
Auditing
Document Control
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Supplier & Incoming
Supplier Quality & Incoming Inspection
AQL-based incoming inspection, supplier scorecards in Power BI, and defect containment. Reduced incoming defect escapes and improved supplier accountability.
Outcomes
- ~35% reduction in incoming defect escapes
- Data-driven supplier reviews
- Audit-ready AQL inspection records
AQL
Supplier
Power BI
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Risk & FMEA
FMEA & Risk Prioritization
Process FMEA with RPN prioritization; action plans for high-risk failure modes. Reduced high-RPN items and improved control plans.
Outcomes
- ~50% reduction in high-RPN failure modes
- Clearer control plans
- Audit-ready FMEA documentation
FMEA
RPN
Control Plan
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Measurement Systems
Gage R&R & Measurement System
Gage R&R studies per AIAG MSA; %GRR improvement and clearer calibration and measurement procedures.
Outcomes
- %GRR < 30% for critical characteristics
- Clearer procedures
- Data-driven gage and training decisions
Gage R&R
MSA
Calibration
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Lean Six Sigma
DMAIC Process Improvement
Full DMAIC project: Define–Measure–Analyze–Improve–Control. Cycle time and defect reduction with sustained controls.
Outcomes
- ~25% cycle time reduction
- Sigma improvement
- Reusable DMAIC template
DMAIC
Lean Six Sigma
SPC
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New Product
PPAP & New Product Launch
PPAP submission per AIAG: flow, FMEA, control plan, MSA, capability, run-at-rate. On-time customer approval and zero launch escapes.
Outcomes
- On-time PPAP approval
- Zero launch escapes (90 days)
- Repeatable launch checklist
PPAP
FMEA
Control Plan
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Analytics
Trend Analysis & Early Warning
Trend charts and leading indicators in Power BI; alerts when parameters drift. Earlier detection and preventive action.
Outcomes
- Earlier detection of process drift
- Fewer customer-impacting defects
- Preventive vs. reactive actions
Trend Analysis
Power BI
SPC
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Problem Solving
Root Cause Analysis (Fishbone & 5-Why)
Standalone RCA using Fishbone and 5-Why for recurring defects. Elimination of recurrence and standard RCA template.
Outcomes
- Elimination of recurrence for targeted issues
- Standard RCA template
- Stronger corrective actions
Root Cause
5-Why
Fishbone
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Quality Systems
Document Control & Revision Management
Document control per ISO 9001: single repository, revision control, approval workflow. One current revision per document and audit-ready records.
Outcomes
- One current revision per document
- No obsolete document use
- Audit-ready records
Document Control
ISO 9001
Revision
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Customer Quality
Customer Complaint & RMA Reduction
8D for every customer complaint; dashboard for complaint rate and 8D closure. Faster response and fewer repeat complaints.
Outcomes
- ~30% reduction in complaint rate
- Faster 8D closure
- Fewer repeat complaints
8D
Customer
RMA
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Process Capability
Process Capability (Cpk) Improvement
Capability studies and improvement (centering and variation reduction) for key characteristics. Cpk > 1.33 and reduced out-of-spec.
Outcomes
- Cpk > 1.33 for critical characteristics
- Reduced scrap and out-of-spec
- Data-driven control limits
Cpk
Process Capability
SPC
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