A high-volume, high-tech industrial design and manufacturing organization announced the next version of its flagship product to the global consumer base. Just before the anticipated product release, the announcement had to be rescinded and production stopped because of production quality problems.
The organization had historically made incremental improvements to its products, but this iteration represented a marked advancement in complexity. It needed a cultural transformation to evolve its quality assurance system, supply chain, and production processes. The goal: to create a quality assurance environment that would be proactive and not reactive when production challenges happened.
The company chose PwC to help address its quality challenges because of our deep manufacturing operations and quality systems experience in multiple high-tech consumer products industries, including pharmaceutical, medical device, automotive, electronics, and automotive. With experience in each of these industries, our diverse team was able to derive relevant practices for the company’s desired quality system.
Working collaboratively with the company’s leadership, we identified three critical goals:
We performed a rapid and broad assessment of the current operations compared to what a similarly situated leading manufacturing company would employ. Industry benchmarks were not sufficient to guide the company, so the team explained lessons learned from other industries’ similar operational transformations to create a customized target.
Among the many systems we helped the client set up were:
PwC advised that it would take a sustained and persistent effort to realize this transformational change, but the initial results are significant.
By improving quality, cutting costs, and speeding up time to market, the client is and moving towards a stable and scalable operation and can retain its place as the global industry leader.