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Spotting potential problems in an international production system
Persistent product quality issues were causing consumer complaints for a global brand. Worth over $400M, the business – an industry technical leader – had successfully reduced the issues, but wanted to understand what was required to completely eliminate them. It asked Innovia to uncover the root causes of this complex multifactorial challenge.
We interviewed experts across multiple international manufacturing sites to compare practices and identify differences in complaint rates. Using these insights, we systematically mapped potential causes of quality problems across the manufacturing process. We then pinpointed intervention opportunities, prioritised them based on their potential impact and ease of execution, and recommended actions to fully eliminate the issue.
The client received a clear summary of the root causes and an actionable assessment of what would be required for full resolution. This has informed future strategy. A technology director described it as “a great framework to discuss challenges, opportunities, and improvement.” Materials generated in this programme will support the training of manufacturing staff, accelerating onboarding and embedding best practices.
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