Project · Quality & Operations
Quality Management &
Non-Conformance Control
Led end-to-end quality management on the production line — from reactive non-conformance treatment to systemic corrective actions, standard work creation and scrap cost reduction — achieving a 20% reduction in scrap and quality costs.
Impact at a glance
Key Numbers
Context
Challenges
Challenge 01
High volume of non-conformances impacting production flow — requiring fast reactive treatment without stopping the line
Challenge 02
Scrap costs representing a significant share of COMS — identifying high-cost recurring defects and eliminating root causes
Challenge 03
Lack of standardized work instructions — operators executing tasks differently, generating variability and quality deviations
Challenge 04
Quality controls insufficient or not systematically applied throughout the process — gaps in MES quality checkpoints
Challenge 05
Limited visibility on scrap costs — no structured tracking making it difficult to prioritize corrective actions by financial impact
What I did
Actions Taken
Non-Conformance Investigation & Treatment — Under 24h
Treated 500+ non-conformances with a reactive approach ensuring production continuity — all critical NCs investigated and actioned within 24 hours to minimize line stoppage impact.
Corrective & Preventive Action Plans
Defined and tracked structured CAPA plans for each significant non-conformance — distinguishing between immediate corrective actions to restore production and long-term preventive measures to eliminate recurrence.
Monthly QSC Meeting — Management & Frontline
Led monthly Quality Safety Cost (QSC) meetings with management and first-line supervisors — presenting serious scrap cases (high-cost NCs), investigation findings and decided action plans. Ensured full transparency and accountability at all levels.
Standard Work Creation & Update — 20+ Instructions
Created and updated 20+ Standard Work instructions to eliminate task variability — documenting the correct execution method for critical operations, integrating quality control checkpoints and making instructions accessible directly at the workstation.
Operator Training on Quality Standards
Delivered hands-on training to operators on quality standards, correct execution of critical operations and proper NC reporting — building a quality-first culture on the shopfloor and reducing operator-induced defects.
Quality Control Reinforcement — Added to MES
Identified process steps with insufficient quality controls and integrated additional control checkpoints directly into MES — ensuring operators are systematically prompted to perform quality checks at critical stages, making quality control mandatory and traceable.
Scrap Cost Calculation & Monitoring
Implemented structured scrap cost tracking — calculating the financial impact of each defect category, prioritizing actions by cost impact using Pareto analysis, and monitoring the cost trend over time to measure the effectiveness of corrective actions.
Outcomes
Results
-20% scrap & quality costs
Sustained reduction in scrap cost and NC-related expenses through CAPA and standardization
500+ NCs treated & closed
All critical non-conformances actioned within 24h — zero production stoppage due to pending NC
20+ Standard Work created
Standardized critical operations eliminating task variability and operator-induced defects
Quality culture strengthened
Operators trained, MES controls added, QSC meetings embedded as monthly governance ritual
Full cost visibility on scrap
Structured tracking enabling data-driven prioritization of corrective actions by financial impact
MES quality controls enforced
Critical checkpoints added directly into MES — quality control mandatory and fully traceable
Stack
Tools & Methods
“Treated 500+ non-conformances with a reactive, data-driven approach — combining terrain investigation, structured CAPA, standard work creation and MES quality reinforcement to achieve a 20% reduction in scrap and quality costs while embedding a lasting quality culture on the shopfloor.”