Problem Overview
In industrial production, quality problems are often visible on the surface, but their root causes are hidden deep within the process. In this case study, we examine how a recurring quality problem encountered in chenille production was systematically addressed and permanently resolved using the A3 Problem Solving (lean problem solving) methodology.
Problem Definition and Data-Driven Analysis
Although the "fabric baldness" problem observed in production with a specific yarn type was initially attributed to yarn quality, the first step of the A3 approach is to define the problem correctly. Our analysis revealed that the issue originated not from mechanical properties, but from a critical parameter in the process, such as the oil ratio.
The root cause analysis we performed with the Fishbone (Ishikawa) diagram showed that the problem arose from cumulative process deviations rather than a single event.
1 Week
Implementation Time
100%
Quality Improvement
Applied Methodology and Solutions
The goal is to identify the problem quickly, make it visible and understandable for all stakeholders, and eliminate it permanently. The process was carried out with the following steps:
Defining the Problem Clearly
With the A3 methodology, the problem was quickly clarified with field data and a common understanding was established for all stakeholders.
Developing Solutions
Root cause-oriented brainstorming was conducted, and the most effective and feasible solutions were selected.
Implementation & Standardization
Solutions were implemented in the field, their effects were verified, and they were integrated into standard processes.
Results and Achievements
- The need for costly and temporary interventions was eliminated.
- Process transparency and predictability were increased.
- Problem-solving competence was integrated into the system, independent of individuals.
- Waste caused by quality problems for this product was reduced by 35%.
- Customer satisfaction was significantly increased.
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