At a well-known international electrical connector manufacturing company, MetaExpert Donald found himself facing a daunting challenge. He was tasked with achieving cost reductions in a product that had been on the market for 30 years, and in the process, he encountered a sudden and unprecedented crisis. The product, renowned for its quality and safety, began to fail quality control tests just two weeks after his arrival. The absence of process documentation and unchecked cost-cutting measures led to alarming field failures, endangering public safety and corporate reputation.
MetaExpert Donald swiftly embarked on a journey to uncover the root causes of this unprecedented failure. Despite a lack of familiarity with the specific product and industry, he leveraged his process engineering expertise and implemented a series of strategic actions:
Through investigation and data analysis, MetaExpert Donald uncovered a surprising and subtle issue - excess heat in the last five feet of the aluminum extrusion process caused a chemical change, compromising the product’s reliability.
After remedying the issue, MetaExpert Donald achieved:
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