Initial situation

A medium-sized company, now listed on the stock exchange,

specialized in lamp production,

vertical integration almost 100% with the production of filaments, electrodes and glass as well as development/production of production lines/machines

at the time of the consultation approx. 6,000 employees in Germany

wanted to introduce a quality management system according to DIN ISO 9001 with TQM orientation for its German plant locations.

The challenge

Quality management was "classically" based on product inspection.

Production and quality assurance had different interests

A QM manual created without management and employees with the intention of achieving certification was described as impractical by the development manager of the plant that had successfully developed and produced the first halogen headlamp for motor vehicles.

Objektive

Change in quality management from control to prevention.

Introduction/application of a certified QM system according to DIN ISO 9001 with TQM orientation.

Reduction of failure follow-up costs.

Approach

Multi-project management in six plant locations.

Structuring of manuals/procedures and work instructions that could be

• applied both across plants and within plants as well as

• accepted and applied by the users.

Information/training/motivation of employees and managers

Introduction of preventive quality assurance methods such as FMEA, SPC and others for failure prevention and avoidance.

Results

A functioning QM system that is recognized by the vast majority of managers and employees.

Significant reduction of failures and failure follow-up costs.

DQS certificate in accordance with DIN ISO 9001.