The Challenge
What needed to change.
A client was suffering from slow throughput, audit risk, and inconsistent quality outcomes driven by manual processes that couldn't keep pace with production demands:
- Slow throughput from manual quality inspections and paper-based travelers
- Audit risk from nonconformances detected too late in the process
- Costly, avoidable rework from inconsistent inspection execution
- Inconsistent record-keeping across shifts and product lines
The Fulcrum Approach
How we solved it.
Fulcrum modernized the factory's quality management system with a digital-first approach fully aligned to AS9100 and DoD compliance requirements.
- Replaced paper travelers with electronic shop-floor travelers integrated into ERP and MES systems, with embedded quality checkpoints capturing data in real time
- Implemented automated dashboards giving leadership real-time visibility into defect trends, nonconformance rates, and operator performance
- Standardized inspection criteria across shifts and product families, reducing variability and improving consistency
- Aligned processes with AS9100 and DoD compliance requirements, embedding audit readiness into daily operations
- Introduced automated workflows for corrective actions, ensuring nonconformances triggered immediate, traceable resolution steps
- Trained inspectors and operators on the new digital platforms, ensuring adoption across the workforce
Impact Delivered
Results that matter.
Outcome
Rework reduced by catching defects earlier in process
Outcome
Improved traceability and compliance audit scores
Outcome
Increased throughput by eliminating paper bottlenecks
Outcome
Raised customer confidence through transparent quality metrics
The factory modernized its quality management system, enabling faster throughput and a stronger compliance posture.