Agile Quality Response in Precision Gear MachiningXiasha Precision Gears, Ningbo China, Machinery & Equipment

Crafts: Agility Operations
Service: Quality Interim Management
Project Date: July 7, 2020
Project_Xiasha_Quality
Xiasha Gear specializes in precision machining of micro-gear components used in robotics and medical automation. In early 2020, the company encountered inconsistent quality yields and a sharp rise in internal non-conformities (NCs).

Eddso implemented a fast-track quality response program targeting real-time defect identification, layered process audits, and operator training feedback loops. Within 6 months, first-pass yield improved by over 4%, and internal NCs decreased sharply.

Challenge

Xiasha Gear’s high-volume micro part production suffered from rising internal NCs, difficult-to-trace defects, and over-reliance on final inspection for quality control.

  • Unstable Machining Process Windows
    Tolerances were too tight for legacy equipment, leading to frequent rework.
  • Delayed Defect Feedback
    Issues were detected too late during batch-end inspections.
  • Lack of Layered Audit Routines
    Middle-layer supervision failed to catch systemic issues.
  • Operator Awareness Limitations
    Quality standards and control points were not fully understood by frontline staff.

Solution

A short-term interim quality control roadmap was deployed, including root cause workshops, visual controls, and layered auditing.

  • Quick-Response Quality Cells
    Daily 10-minute defect huddles and feedback boards were introduced.
  • Process Window Validation (PWV)
    Controlled trials to re-define critical machining tolerances for key parts.
  • Layered Process Audit (LPA)
    Cross-functional auditing covering operators, line leaders, and engineers.
  • Visual Standard Work
    Poka-Yoke visual guides and defect libraries placed on machines and checklists.

Milestone

STEP

Demand Alignment

STEP

Onsite Investigation

STEP

OpEx Solution

STEP

Implementation

Results

A measurable uplift in quality consistency and agility in response was observed across lines.

  • +4.1% First-Pass Yield
    Yield rose from 92.1% to 96.2% over 6 months.
  • Reduced Internal NCs
    Total internal NCs dropped by 37% in Q2.
  • Audit Coverage Tripled
    Monthly audit coverage tripled from 2 to 6 lines, with full cross-functional involvement.
  • Shorter Feedback Cycles
    Average detection-to-action response time reduced by 60%.

How Quality Interim Management improves Process Stability?

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