THE GOLDEN CYCLE

"The GOLDEN CYCLE" is a Methodology which is developed by my own experience and can be used for Solving Quality and Technical Problems in any Manufacturing Process. Problems like higher than "0" or planned failure or defect rates, some high efforts for rework, processes and process-times, reverse-testing or part-stocks and other inefficiencies. Not only internal failures, but as well external failures can be reduced. The Approach is Proactive in Development/ Planning phases or "Reactive" in Production/Manufacturing for still existing machines and processes. But, the measures for improvement are still Proactive. Prevention based, because the during the usage of the Approach some Measures/actions are implemented, although it starts with Detection, means finding the cause(s) for the Manufacturing problems. The GOLDEN CYCLE consists out of 3 phases resulting in the 4th point: 1. Accepted Standard (working) PROCESS, 2. Effective QUALITY Tools and 3. Essential TECHNICAL Support resulting in 4. PERFORMANCE Increase #1 is the Accepted Standard PROCESS: this includes a Commitment from Executives with employees, a suited Shop-floor Working Place, and, a suited Working Process. Acceptance, but as well core elements like leadership, curiosity, transparency and confidence are the key! I use the PDCA-Cycle from first Shewhart, Deming and Kaizen as the Standard Working Process. Added with an own so-called "Couple-principle": P and C phases the Controller and in D and A phases Converter is responsible. In phase #2 Effective QUALITY Tools and Methods from TQM, Kaizen and Six Sigma are used. Here in general and my own common sense is important. The right tool or method for each step. "Less is sometimes more". Otherwise the employees and management as well could be overstrained. Especially phase #3. Technical Support guarantees a more effective and efficient Approach than without. That's the difference to Kaizen, because solving deep and multi-dimensional failure causes is almost impossible with Kaizen. The complex Six Sigma DMAIC Methodology makes it possible finding the key Xs or failure-causes which are responsible for the planned result Y after Y = f(x). But, it's by own experience in some complex manufacturing products for complex products like vehicles, machines or IT products with nonrandom sometimes multi-dimensional failure causes based on poor product or process design almost impossible to go this systematic approach efficient! Therefore I add in my GOLDEN CYCLE Approach in #3 the Technical Support by own experience as well as asking (confidential) external experts. Like Albert Einstein said: "We cannot solve our problems with the same thinking we used when we created them"