Our client is the undisputed market leader in delivering integrated systems for the semiconductor industry. Its customers include the world’s largest electronic chip manufacturers. Sustaining Moore’s Law brings along a gigantic complexity: balancing the right tradeoffs between innovative functionalities, unique performance levels, perfect quality and competitive design-to-cost sub-systems. Up to the point where system upgrades or even new installs show reliability issues from the start. As highprofile customers expect zero defects, the company management is fully aware that a rapid and all-encompassing response is needed to turn the tide. They decided to roll-out a company-wide quality excellence programme.
This is a fun way to brainstorm around ideas and work out plans on issues that we are confronted with in our daily workParticipant Make It Well Inspiration Game
The initial analysis indicated several critical areas of improvement. 2 pressing topics were addressed first: the increase in reliability issues (Dead-On-Arrivals) or DOA's, and improving field diagnostics. Despite all the effort on DOA avoidance over the past two years, the numbers of DOAs was not going down. They had not yet found the root cause of these defects. A cross-functional collaboration was needed to move the needle and investigate structural solutions together with all important in-company stakeholders.
The company chose the Inspiration Game to mobilize managers, executives, and representative experts from all relevant departments and competences, and make them collaborate closely the critical topic of Dead-On- Arrivals (DOAs). The challenge was baptized the Zero DOA Game, and fits within the internal ‘Make It Well’ programme. The participants were asked to help reducing the number of DOAs through structural prevention measures, and identify new root causes for the defects. The ultimate goal was to convert the learnings of DOA cases into structural improvements, while raising awareness on the importance of quality culture and zero DOAs.
31 active representatives from different departments came up with 57 ideas on how to approach zero defects upon delivery. Gathering these cross-functional insights allowed for the identification of 2 overarching root causes. A structured solution tree was built to address each root cause via product, feature, process, technology, and governance measures. After several workshops, Venture Spirit grouped the different platform insights, identifying and selecting 13 priority quality enhancement clusters ready to be put on the roadmap for implementation.
I had a lot of ideas but no chance to share them. The game was a great motivation for me. I hope to get these opportunities continuously. It is my pleasure to share the ideas all togetherWinner Make It Well Inspiration Game
- Acceleration of expertise sharing on a global scale and cross-functionally
- Identification of underlying causes of defects and structuring of new and know information into a framework ready to be rolled out
- Awareness raised on the importance of high quality standards and living up to them
- Participants highly appreciated the chance to contribute to a major company challenge anonymously