The challenge

Within less than two years, the TE – Connectivity ZKS Tát site progressed from project launch to having three production lines with validated SOPs. However, the quality performance faced a lot of challenges due to a complex set of factors. Limited time and recourses were available for structured problem-solving, team reflections, and there were challenges in consistently applying the 8D methodology in teams and continuously improving and stabilizing the effectiveness of outgoing quality.

Our approach

• The program, running from July 2024 to February 2025, was built on five pillars: Man, Machine, Measurement, Method, and Management. We were present on-site in an interim project manager role, providing daily operational support.
• We introduced a KPI system, structured feedback loops, daily scrap meetings, 8D problem-solving, process audits, and visual leadership tools to support behavior change.

The results

• The primary goal was to replace intuition-based reactions with fact-based, routine-driven quality operations at all levels.
• As a result, COPQ trends stabilized, quality KPIs became actionable, and the structured problem-solving culture (8D, 6S, visual inspections) was reinforced.
• One of the production line served as a benchmark in the improvement process..