Defect Reduction

Defects are embarrassing! This is also a huge cost to the company as every defect initiates a series of rectification and support activities. These activities are larger than the normal processes and are termed as a “Hidden Factory”. Eliminating defects requires a holistic approach. Knowledge of the related process, root cause analysis (RCA) competency, and team approach becomes essential.

How Do We Do?

• Measure the defect, its quantum, and impact accurately to prioritize
• Form a team comprising expert of the process
• Understand the complexity of the problem and decide on the approach of RCA (P-M analysis, Correlation, Regression, Design of Experiment, 7QC tool, advance 7QC tool, or any other as applicable)
• Analyse the problem and find out the root cause
• Plan actions, improve and standardize for sustainability

Implemented At:

• Tecumseh Products India Ltd.
• Gabriel India Ltd.
• Eastman Auto and Power Limited, Baddi

Duration 3 – 12 months