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“We operate where technology leaves no room for error.”

Downtime! Quality Issues! Delivery Delays!

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Scrap Reduction and Product Release

using detailed failure diagnostics, maturity level reviews, and technical appraisals – also covering casting, welding, and joining technologies.

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Stabilization of Series Production Processes

through structured escalation and change management.
Failure resolution and production release – directly on the line or within task force structures.

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Stabilization of Critical Suppliers

through firewall measures, 8D reporting, SPC, inspection strategies, and aligned recovery plans – also across international supply networks.

Availability: within 48 hours – anywhere in Germany.
Contact us via message or directly at:

       info@holzschuh-consulting.com
       +49 151 4313 3508

When things get critical, experience makes the difference.
With Holzschuh Consulting, you gain rapid access to hands-on technical support to stabilize your series production – right at the line, on-site at your plant, or directly at your suppliers.

We analyze, stabilize, and implement – with clear focus, deep system understanding, and technical authority.

 

Whether it’s scrap reduction, production release, or supply chain recovery –

we make your processes work again.

Production - Case Study

Cast Component for an Exhaust Turbocharger – Duration: 6 Months

Result

  • 30% reduction in error rate through targeted training of production personnel

  • 25% decrease in false rejects, resulting in a higher share of components being cleared for direct delivery

  • 18% reduction in scrap-related costs, as defect-free parts were no longer mistakenly discarded

  • Lead time shortened by 2 days, due to fewer components requiring reinspection

  • 100% supply chain continuity, enabled by resolving uncertainties in defect evaluation

  • 10 concrete improvement proposals for the TIER 1 defect catalogue, 8 of which were implemented immediately

Objective / Challenge

  • High scrap rate: A significant number of cast components for an exhaust turbocharger were withheld from delivery due to uncertainty about which parts met quality standards

  • Uncertainty in defect evaluation: Employees were unsure which defects were acceptable and which required rejection

  • Unclear process boundaries: Defects originating from upstream processes (TIER 3) impacted quality outcomes at TIER 2

  • Inadequate defect catalogue: The existing defect catalogue provided by TIER 1 was impractical to implement in daily operations
     

Solution Approaches

  • Scrap evaluation and defect analysis: Comprehensive inspection of all components at TIER 2 based on the defect catalogue

  • Cross-process defect tracking: Identification and elimination of faulty upstream processes at TIER 3

  • Defect catalogue optimization: Practical improvement suggestions provided to TIER 1 for better applicability

  • Detailed defect documentation: Recording of defect types, locations, and frequency for root cause analysis

  • Employee training: Development of a visual defect catalogue and targeted training to improve defect recognition

  • Knowledge transfer: Direct feedback to casting, cleaning, and machining departments to support process optimization

Applied Expertise

  • Technical process knowledge: In-depth analysis of casting, finishing, and machining processes

  • Quality management experience: Strong expertise in defect catalogues and evaluation systems

  • Analytical and optimization skills: Identification of faulty process steps across the entire supply chain

  • Hands-on training competence: Delivery of practical, results-driven training sessions for production teams

  • Technical hands-on mindset: Active presence on the shopfloor – not just strategy, but real, applied engineering

Holzschuh Consulting delivers measurable results – fast, focused, and built to last.

TQM - Case Study

Battery Module Housing for HV Battery – Duration: 6 Months

Result

  • 70% reduction in scrap rate through the introduction of a new defect and inspection catalogue combined with targeted rework measures

  • 20% cycle time reduction in prototype production via detailed target–actual analyses and process optimization

  • 12% reduction in production costs, achieved through welding process optimization and more efficient rework procedures

  • 50% defect rate reduction in housings by identifying previously undetected production issues and adapting inspection protocols

  • 100% supply chain reliability ensured by implementing a quality firewall and avoiding costly returns

  • 4 specific cost-saving opportunities identified – 3 of which were successfully implemented

Objective / Challenge

  • Critical TIER 2 supplier for battery module housings faced with severe quality issues

  • High scrap rates caused by defective housings that repeatedly passed final inspections unnoticed

  • Defective weld seams and unclear root causes in the production process

  • Inefficient prototype production due to missing cycle time analyses and high manufacturing costs

  • Lack of alignment between TIER 1, TIER 2, and TIER 3 regarding quality standards and process parameters

  • No transparency on optimization potential across the entire process chain


     

Solution Approaches

  • Developed a defect and inspection catalogue for systematic classification of housing-related quality issues

  • Established a firewall function between TIER 2 and TIER 3: final inspection and rework managed independently

  • Supervised weld seam validation and optimized welding processes at TIER 2

  • Assessed the impact of surface coating on product quality and initiated necessary process adjustments

  • Implemented statistical process control (SPC) to identify and reduce welding defects

  • Conducted cycle time analyses across the entire prototype process chain (welding, assembly, cleaning, final inspection)

  • Performed root cause analysis using defect clusters (man, machine, material, method)

  • Reviewed TIER 1 design specifications (drawings, tolerances) for practical feasibility and proposed optimizations
    Delivered employee training on new processes and inspection standards

  • Identified potential ramp-up risks and developed preventive measures
    Introduced cost-saving initiatives and quality improvement actions
     

Applied Expertise

  • Technical process expertise: Extensive experience in welding, assembly, machining, and quality management

  • SPC and process analysis know-how: Application of statistical methods to minimize defects

  • Supplier management experience: Effective coordination between TIER 1, TIER 2, and TIER 3 stakeholders

  • Hands-on mentality: Direct on-site involvement across all critical process stages – from final inspection to rework
    Training competence: Transfer of technical knowledge to enable sustainable process improvements

  • Project management skills: Structured execution of a recovery plan focused on quality, cost, and delivery time










     

Holzschuh Consulting:
Delivering measurable results through technical excellence and on-site execution.

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