Projects / References
Selected projects in the areas of Early Phase, Project Work, Task Force and Audit:
Early Phase
Production Analysis - Components with Defects
Context
A manufacturer of water-bearing components repeatedly delivered products that leaked at the customer site, even though tests prior to delivery often showed no leaks.
Approach - Collaborating with the Supplier via a Problem-Solving Team
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on-site analysis of potential causes together with relevant stakeholders
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Identification of weaknesses in the production process
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Definition of action steps for targeted follow-up
Solution
Professionalization of quality control: transition from manual inspection of sealing surfaces to objective camera-based monitoring
Result
Process standardization, sustainable improvement of quality control, and reduction of delivery of defective component deliveries.
Project Work
Long-Term Project Support and Management
Context
In a project for an automotive OEM, all committee activities, work packages, and decisions had to be efficiently managed and transparenty communicated over a period of 30 months.
Approach
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Committee management: agenda, facilitation, and minutes
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Tracking of the seven work packages
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Organization and coordination of workshops
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Consolidating of content for weekly and monthly reports
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Preparation of decision documents and presentations
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Updating organizational charts and profiles
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Conducting lessons learned, including interviews with approximately 30 participants, to continuously improve processes
Solution
Structured process management and consistent tracking of all project content throughout the project duration.
Result
Efficient committee work, transparent decision-making foundations, and complete traceability of all topics over 30 months. All work content was executed consistently and on time; decision-making processes were conducted on a well-founded basis.
Task Force
Start of Production - Acoustic Deviation Door Lock
Context
During the SOP ramp-up, vehicles exhibited sporadic rattling noises in the door lock with notable frequency.
Approach - Collaborating with the Supplier via a Problem-Solving Team
Analysis of the interaction between rotary latch and pawl, including test series for tolerance and mating evaluation.
Solution
Exclusion of critical measurement combinations and defined lubrication plan.
Result
Measures were defined, validation completed, and serial implementation carried out within a few weeks in the next change index. The issue was permanently resolved.
Audit
VDA 6.3 - Escalation Case Successfully Stabilized
Context
A first-tier supplier was at "red" escalation level following a failed VDA 6.3 audit. The customer demanded immediate, reliable evidence of process stability.
Approach
Structured handling of all audit-relevant action areas: periodic review of critical deviations, verification of the effectiveness of implemented measures, and targeted preparation for the follow-up audit.
Solution
Systematic closure of deviations, including process documentation, internal validations, and audit-readiness assurance.
Result
Follow-up audit successfully completed after three weeks. Escalation status lifted, rating "green". Process stability sustainably secured.