Flawless production? Quite simply: all influencing variables and parameters must be identified and considered holistically. Reality shows, however, that this is not so easy – on the contrary, it is even very complex.

Looking at the entire manufacturing process in one piece, this may lead to process improvements, but definitely not to a complete process assurance. So what is necessary? First, only the one partial step is looked at more closely where the biggest problems or the highest costs are known. The substep that hurts the most, so to speak. Exactly for this one substep, all influencing variables and parameters that secure the step must be determined and analyzed. This information forms the basis for the next step to determine which technologies, systems, software and skills are required to secure the process step. With a consequent and on this partial step focused working method, a solution results within a short time, which secures exactly this process step. And the result? Zero errors and measurable success.

Step-by-step to complete process protection

This procedure is now carried out and implemented one after the other for each individual substep. More and more the processes are safeguarded until a complete process protection has been created. And the best thing about it? This procedure also allows you to react quickly to changing conditions or unknown errors. Because if new requirements arise during processing, if existing requirements change or if unknown errors occur, this point can be intervened quickly and effectively. However, these changes can in turn have an influence on previous or subsequent process steps. These interactions must also not be forgotten. However, this interaction can be planned in and taken into account from the outset when processing the subsequent process steps.

So what leads to success?

The focus of the whole model is on the step-by-step approach. This, in combination with the iterative approach of the solutions, brings measurable, visible and above all rapid success. This in turn motivates all parties involved and ensures a high level of acceptance.

But what does the whole thing look like in practice? We have an example of this, which we will present in the next article.

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