Solving customer problems is what we do best! That’s why one of our customers came to us with a challenge.
A leading tire manufacturer had been facing a persistent challenge in tracking and addressing quality issues within its production process. Despite having a quality assurance protocol in place (which included sign-offs at various production stages), the company struggled to pinpoint the exact location and timing of quality problems. It needed to minimize customer complaints and enhance overall product quality—fast.
The distributor came to Wise, seeking a solution.
Needing a Solution — Fast!
To address the issue, the distributor worked with Wise to take a deeper look at the customer’s manufacturing and distribution process. Upon close examination, Wise identified a crucial gap in the quality form accompanying each order. The form the manufacturer was using lacked the ability to specify when (i.e., during which shift) a quality problem occurred.
Wise proposed using their existing barcode readers and adding a barcode that would be scanned by the operator at key stages: upon receiving a job, during its execution, and upon completion within a specific department. This simple addition would provide a granular timestamp for each quality check, enabling a more precise identification of when issues occurred.
ReDesigned Form Yields Results
The distributor made the proposal to the tire manufacturer, who loved the idea—and it paid off. The redesigned quality form yielded significant improvements. The addition of barcodes allowed the company to trace the exact shift and operator responsible for a specific defect. This newfound level of detail, in turn, enabled the manufacturer to initiate targeted employee improvement plans and document refined processes for all staff members involved.
The tangible outcomes were impressive. The tire manufacturer saw a remarkable reduction in defects, achieving an overall decrease of over 10%. This not only addressed the immediate quality concerns but also positioned the company as a more reliable and quality-focused supplier.
The distributor who proposed and implemented the barcode-enhanced quality forms secured the order for their services across more than 60 distribution centers. The demonstrated impact on quality control became a key factor in earning the trust and long-term partnership.
Key Takeaways . . .
- Precision in tracking: Incremental barcoding enabled precise tracking of quality checks, identifying the specific shift and operator associated with defects.
- Targeted improvement: The newfound data allowed the tire manufacturer to implement targeted improvement plans and document refined processes for enhanced quality assurance.
- Significant defect reduction: The initiative resulted in a notable decrease of over 10% in overall defects, contributing to improved product quality and customer satisfaction.
- Expanded business opportunities: The success of the solution not only addressed the initial challenge but also led to expanded business opportunities, securing the distributor’s services across a vast network of distribution centers.
Need help solving a customer workflow challenge? Partner with us. Wise specializes in automotive forms and has decades of experience in this market.
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