The development and production of high-quality cables made the client one of the leading manufacturers in this segment. Once specialized in small-scale manufacturing, the company has evolved ability to produce high-volume tailor fit to meet customers need on an order-by-order basis. The increased complexity associated with rising production volume called for process-oriented realignment in manufacturing and other associated activities. Our main task was to document this realignment as well as the related product quality for the client as a foundation for future growth.
Overview
Significant growth helped the cable manufacturer obtain a leading position in the onshore and offshore high-voltage cable market.
The transition from small-scale manufacturing to mass production.
Challenge
Optimizing processes and documenting manufacturing-related product quality.
Standardizing processes and reflecting the corresponding transparency within a company – along with defining and documenting related processes and dealing with potential deviations – are essential when production output rises. Processes that were not time-sensitive in the past when production volumes were lower, suddenly create a bottleneck and need to be optimized. Since manually intervening in the manufacturing process is often no longer possible, existing manufacturing processes must be reviewed using state-of-the-art quality techniques to assess their reliability and sustainability. Both manufacturing quality and customer demands have to be documented as part of the process.
Understanding and implementing new processes and procedures is essential. This calls for cultural change within the company.
Solution
Moving beyond an isolated view of the change process in manufacturing
Drawing up standardized operating procedures, process and control plans, acceptance standards and much more formed the foundation for further optimization potential. Advanced methods such as Six Sigma allowed us to optimize processes in a variety of areas. In addition to physical implementation, supporting participation in regular communication and the associated supervision of cultural change within the company also played an instrumental role. Only by doing so could the changes introduced result in lasting improvement.
Process-related documentation forms the foundation for digitalization.
Real-time product documentation as part of the process was a further challenge. The creation of a handover package for the client that contained all the necessary documents was merely the result of measurements and tests. Specifications were also drafted to serve as a foundation for customer documentation over the course of the quality assurance department’s digitalization in the years ahead, enabling the client to forgo the manual creation of documents and make all documents available at the touch of a button in the future. This will save resources, significantly enhance the quality of documentation and ultimately increase customer satisfaction.
Outcome
Lasting implementation of consistent, reliable manufacturing quality.
Over the past two years, the client has succeeded in significantly improving the reliability of processes in manufacturing. Product non-conformity has fallen by 50 percent, and manufacturing costs have been reduced. Today, non-conformity management extends beyond manufacturing to include suppliers and customers and inform them promptly and transparently, increasing customer satisfaction.
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