After a major capacity increase, the client was confronted with a scrap rate of more than 10% in their overmoulding production process. The primary challenge was the lack of a reliable checking device, making accurate defect detection nearly impossible. As a result, neither the source of NOK parts nor the true process capability could be clearly identified.
Our consultants from KCG conducted a complete analysis of the production process and part design. Using structured problem-solving methods such as ISHIKAWA, 5 Why, IS-IS-NOT and Failure Tree Analysis, combined with statistical tools like DOE, MSA, SPC, dimensional reports and 3D scans, we identified key contributors to the quality issues. Daily coordination with the customer’s task forces ensured full transparency and fast decision-making.
A major breakthrough came with the design and implementation of an interim Go/No-Go quick-check device (ICA). This allowed the customer to filter out NOK parts directly in their plant, reducing the scrap rate from >10% to below 5%. Further analysis revealed that the part design and process could not consistently meet the tight ±0.2 mm tolerances, and the existing EOL measurement system was not capable of controlling such precision.
To close this gap, we designed a new, highly accurate Go/No-Go checking device for 100% EOL inspection and documentation. The new system fulfills AIAG MSA 4th edition requirements and ensures reliable identification of NOK parts, supporting long-term process stabilization. Additional workshops, value stream mapping, R@R studies, and layout optimization helped the customer increase OK output while sustainably reducing scrap.