In 2017 we engaged three of RiverRouge’s Interims to lead our Quality initiative and push through significant changes across our process spectrum. The consultants immediately seamlessly connected with the organisation and established themselves as respected colleagues as opposed to “external consultants”.
Hitec Power Protection – Engineering Quality, Supplier Development and Rework Support
Our Client an Organisation in Holland was manufacturing large scale Power Generators for critical Process Back-ups for server farms of Banks and Internet Giants and other critical equipment. At the time of engagement the manufacturing and engineering process showed crucial gaps in terms of quality assurance which had a direct impact on defect occurrence in end-of line testing and field failures. As these generators were the last line of defence in their client’s energy network defects in the field lead to detrimental impacts so we were asked to conduct a complete review of the approach to Quality from Engineering to the field operations to stabilize product robustness.
- 360 degree Baseline Audit of the entire business operation based on VDA 6.3 criteria
- Implementation of robust engineering principles such as DFMEA and Maturity Level Analysis
- VDA based implementation of an internal Supplier Development team
- Structured and led a maintenance and rework initiative of the companies installed capacity in the field
- Resident Support at some critical Suppliers
- Hands on Rework Support on generator flywheel parts to rectify a supplier quality defect
After 18 months the following improvements were evident:
- Zero Failure rate in End of Line testing
- Crucial Risks of installed capacity in the field Assets had been eliminated through a comprehensive rework and maintenance initiative that led to significant reduction of field complaints and power-cuts
- A proactive supplier development team was established working through a systematic VDA structure on quality and cost improvements throughout the supply chain
- The customer satisfaction feedback on field defect rates and responses increased significantly
