Aubert & Duval launched a taskforce to deal with 1,500 discrepancies in 12 weeks, with the objective of bringing the non-conformance rate below 3% of rework. Thanks to strengthened coordination, the teams were able to restore the expected quality.
12 weeks
France
Nuclear
Aubert & Duval
As part of its metallurgical activities, Aubert & Duval identified a significant number of non-conformities affecting the quality of its production. These differences, linked to customer specifications and standards in force, could affect the reliability and performance of the parts produced. In order to restore an optimal level of quality and to maintain the trust of its partners, the company decided to set up a “Taskforce DD” (Exemption File) with the help of internal and external experts.
The mission, conducted over 12 weeks, involved 25 engineers specialized in gap analysis, the preparation of technical arguments and the drafting of exemption requests. The objectives were multiple: to qualify the impact of non-conformities, to carry out in-depth risk analyses, to propose additional tests, and to formalize each discrepancy in the form of a sheet, in order to take appropriate corrective measures. A platform of 12 FTEs (Full Time Equivalents) was present at the client's premises, while 13 FTEs worked in the back office. Management, coordinated using production indicators, made it possible to maintain a steady pace, going so far as to deal with 1,500 discrepancies within the set deadline. This organization resulted in a rework rate of less than 3% and a quality level of 97%, thus meeting Aubert & Duval's requirements to satisfy its customers.
Aubert & Duval wanted operational support to deal with the 1,500 discrepancies identified in record time. The challenges were risk management, technical arguments and compliance with customer specifications and industrial standards. The final objective: drastically reduce the rate of non-conformities, maintain customer confidence and improve the quality of productions while maintaining delivery rates.
Identify the impact of each non-compliance and limit rework to below 3%.
Quickly structure and write exemption requests (80 forms created).
Achieve 97% quality thanks to detailed management and a team of 25 engineers.
The DD Taskforce mobilized a variety of skills: metallurgy, project management, project management, statistical analyses, risk studies, etc. This multidisciplinary approach encouraged the rapid drafting of non-conformity sheets and the preparation of technical arguments. Reinforced management (“S” curve, performance monitoring, reporting by type of discrepancy) made it possible to visualize progress and adjust the pace of production. Thanks to two weeks of onboarding, the team was immediately up and running, significantly reducing deadlines and achieving a high quality rate.
Coordinate a set of 12 FTEs at the customer's premises and 13 FTEs in the back office.
Use real-time monitoring (S-curve) to control the pace of treatment.
Mobilize 25 engineers and finalize the service in 12 weeks, for 1,500 discrepancies treated.
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