Benchmarks & Client Cases 

Quality Improvement in Discrete Assembly

The Challenge




• Over £200,000 cost of non-quality parts per year

• 744 hours dedicated to reworking each year

Root Causes

• High variability across the assembly tasks, resulting in outputs of differing qualities

• Ad-hoc resolution of non-quality incidents, with no permanent countermeasures being incorporated into the responsible process

• Lack of visibility of all the non-quality problems and their root causes

The Solution


• Implementation of a Control & Detection system to identify non-quality incidents as soon as they occur and mitigate them - Non-Quality Matrix

• Development of Structured Problem-Solving capabilities at Team Leader and Group Leader levels

• Development of a "Stop Scrap" system that allows for the sustainability of the quality improvement activities

• 105 3C initiatives concluded in an effort to solve minor quality causes 

The Results

The project had a Payback period of 3 months with annual savings surpassing £307,000.


Non-quality cost

Cost of non-quality parts reduced by 51%


Hours of rework

Hours of rework required to correct non-quality issues reduced by 33%

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