Quality Engineer Builds His Very Own AI-Powered Data Precision Analyst

Based at the Akkodis offices in Vesterås close to Stockholm, Johan Lindqvist works as a consultant for a large Swedish manufacturer of high-quality industrial equipment. He is responsible for securing the highest possible quality of components coming from 26 different component suppliers. For instance, he controls that the size of metal parts lives up to specifications, that welding is done correctly, and that rubber parts comply with the required quality.

They must get past Johan

Before suppliers are allowed to ship anything to the factory, they must get past Johan. As the person in charge of supplier quality he is tasked with reviewing the material suppliers provide to document that the components they’re delivering live up to the agreed standards and tolerances.

• If I discover any issues, I get back to the supplier to discuss the problem. Johan explains.
• Often, I help them pinpoint the cause of the problem and together we find a way to minimize it, or preferably eliminate it altogether.

It can be time-consuming and tedious work to review components to maintain a certain level of quality. As some measurement documents with for instance drawing dimensions can contain up to 250 measurements, going through them manually is laborious. But AI can help.

• It just takes forever, and I thought maybe AI can help? I went to my boss Jimmy Lundberg to discuss it with him, and we agreed to give it a try. So, I created a custom GPT and have trained it to help me with both mundane tasks as well as advanced calculations. It is my own assistant precision data analyst, and it’s already making a huge difference in my daily work.

Feedback within seconds

As an example, Johan feeds Excel sheets into his custom GPT containing data about specific components, comparing required dimensions with actual dimensions. Within seconds he gets back an overview of critical points that require his attention. Without his new AI-powered precision data analyst it would have taken him hours of manual labour to pinpoint the problems.

Also, the system helps him use tools to solve quality issues, like RCA (Root Cause Analysis), the DMIAC improvement cycle (define, measure, analyse, improve, control) or SWOT analysis (strengths, weaknesses, opportunities, threats). Johan feeds a short, plain text description of the issue at hand into his custom GPT, and it outputs a nicely structured roadmap for tackling the issue (see fact box).

• Just a few days ago I asked it to perform a Root Cause Analysis for a supplier having welding quality and late delivery problems. I told it to present it both in English and Swedish, and it took 21 seconds. That is about the time it takes me to find my pen.
• However, I would like to emphasize that while I am using the AI to create outputs like Lean Six Sigma and SWOT, it’s not better than actually doing this in a group. But using AI to get a broad picture of the problem to show to a group for it to come with additional input, and then put that into the AI will surely create something really valuable.

Writing reports is another task well suited for AI assistance. Johan Lundqvist writes numerous reports every week. Provided that it is directed by a good, well refined prompt the custom GPT saves hours of report writing work.

Advanced calculations

Furthermore, he is using his custom GPT for advanced calculations. As an example, he tasked it with calculating how much a plasma cut hole in a piece of metal would shrink because of the welding. As he didn’t have the exact data regarding temperature, gas flow etc. it had to be a theoretical calculation, using the mathematical formula Δd=d×α×ΔT.

• If I had to calculate that myself, it would take hours. Although the calculation is theoretical it works. I showed it to one of the welding engineers in the company I’m working for. He has 25 years of experience with welding, and he was really impressed.

Johan Lindqvist estimates that his new AI-assistant saves him a lot of time. How much depends on the specific task, but somewhere between a few minutes to several hours.

Continuous improvement

However, saving time is not the only upside of having your own data precision analyst. Most importantly, according to Johan, it buys him time to focus on what really matters. And in the world of supplier quality engineering, what really matters goes under the abbreviation CI. The two letters stand for Continuous Improvement.

• Instead of being completely caught up in putting out fires from morning to night, now I’m saving so much time due to the custom GPT that I can focus on continuously improving my own work and the work of the 26 suppliers I’m overseeing. That obviously reflects on the quality of the components coming from the suppliers. And not least, it makes my job and the quality of my work so much better.

Business manager Jimmy Lundberg is now looking into, how the impressive results Johan Lindqvist has achieved with ChatGPT can inspire the other 30 Akkodis consultants working out of the Vesterås offices.

• It started as a trial to see if generative AI could be useful to us. Now it is my ambition to implement AI in other areas, and I’m sure the other members of my team will find many similar use cases relevant for their line of work. This initiative proves that AI isn’t just for techies anymore. In my opinion it is relevant for every role within Akkodis.

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Johan Lindqvist has asked his AI-powered data precision analyst to become a Black Belt Six Sigma expert to do advanced SWOT analysis. To his delight, it now makes a DMAIC based on the SWOT automatically in the same output which is highly effective and time saving.

Prompt:

Now as the master Black Belt Six Sigma expert that you are let’s write a SWOT together and see what angle we need to tackle this problem. I am poised to embark on an in-depth SWOT analysis for a company currently facing significant challenges with their glue's adhesive properties. This situation is mitigated by the presence of an outstanding Quality Department within the company. The team exemplifies exceptional skill and openness to feedback, effectively incorporating the customer's voice into their improvement processes. This dedication to continuous enhancement is pivotal, suggesting a strong willingness to refine their product for the broader benefit of all customers. However, a notable challenge is the company's factory location, which is situated in a remote area. This location is characterized by its limited accessibility, making frequent visits for direct collaboration highly impractical. Despite this logistical complication, the strategic positioning underscores the company's commitment to privacy and focused innovation, away from the bustling distractions of urban centers. The constraints on accessibility, while presenting certain logistical challenges, also offer a unique opportunity for leveraging digital communication and project management tools to facilitate collaboration. This approach to overcoming geographical barriers not only demonstrates adaptability but also aligns with modern practices of remote teamwork and problem-solving. By embracing these challenges as opportunities for innovative collaboration, we anticipate realizing significant cost savings and product improvements. This concerted effort, despite the limited physical accessibility of the factory, is expected to enhance the quality of the adhesive product significantly, fostering a stronger business relationship and leading to an increase in orders over time.

Output:

Embarking on a SWOT analysis with the scenario you've outlined, let's assess the Strengths, Weaknesses, Opportunities, and Threats for this hypothetical company dealing with adhesive product challenges. As a Master Black Belt in Lean Six Sigma, our focus will be on identifying areas for process improvement, waste reduction, and quality enhancement, aligning with the principles of continuous improvement and customer satisfaction.

# SWOT Analysis

Strengths:

1. Exceptional Quality Department: A dedicated and skilled Quality Department capable of identifying and addressing product issues, and open to integrating customer feedback into the improvement process.
2. Commitment to Continuous Improvement: The willingness to continually refine and enhance products based on customer needs and feedback, indicating a proactive approach to quality management.
3. Innovative Collaboration: Despite geographical limitations, the company's readiness to employ digital communication and project management tools for collaboration shows adaptability and a forward-thinking approach.

Weaknesses:

1. Adhesive Product Performance: The core issue with the glue's adhesive properties directly impacts customer satisfaction and the product's market competitiveness.
2. Limited Accessibility of Factory Location: The remote location hinders frequent, direct collaboration and may delay the iterative testing and improvement cycle necessary for product development.
3. Potential Logistical Challenges: Remote location might complicate logistics, affecting the supply chain, raw material delivery, and distribution of the final product.

Opportunities:

1. Digital Transformation: Utilizing advanced digital tools for project management, virtual collaboration, and remote testing can minimize the impact of physical barriers, opening new avenues for innovation and efficiency.
2. Market Differentiation: By solving the adhesive issue and leveraging the unique aspects of their operation, the company can position itself as a niche player offering specialized, high-quality adhesive solutions.
3. Strategic Partnerships: The challenge of accessibility could encourage partnerships with local logistics companies or the development of innovative delivery solutions, enhancing supply chain resilience.

Threats:

1. Competitive Pressure: If the adhesive problem persists, there's a risk of losing market share to competitors with more reliable products.
2. Brand Reputation: Ongoing product issues could damage the company's reputation, making recovery and future market penetration more challenging.
3. Operational Risks: The unique challenges posed by the remote location could lead to operational inefficiencies, impacting the company's ability to respond quickly to market or customer needs.

Tackling the Problem: Lean Six Sigma Approach

Given this SWOT analysis, tackling the adhesive product issues through a Lean Six Sigma approach involves several key steps:

1. Define the Problem: Clearly articulate the adhesive issues, including specific customer complaints and internal quality metrics.
2. Measure Current Performance: Collect data on the adhesive's current performance, identifying specific failure modes and the frequency of these issues.
3. Analyze the Data: Use Six Sigma tools to identify root causes of the adhesive failures. This might involve chemical analysis, process mapping, and examining the supply chain for quality variances.
4. Improve: Develop solutions to address the root causes. This could include formula adjustments, process changes, or supplier quality improvements. Engage the Quality Department in iterative testing and refinement, using virtual collaboration tools to involve all stakeholders.
5. Control: Implement new quality control procedures to ensure the improvements are sustained. Monitor performance closely, using digital tools to track quality metrics in real-time and respond promptly to any deviations.

By systematically addressing the adhesive issues with a focus on quality improvement and customer satisfaction, the company can overcome its current challenges, leveraging its strengths and opportunities to mitigate weaknesses and threats. This strategic approach will not only enhance the product's quality but also strengthen the company's market position and customer relationships.