The problem
A stacked-component interference condition was creating rework and preventing units from being sold. The issue crossed drawing intent, weldment variation, installation procedure, and quality control.
Root cause to corrective action
I traced the failure through the assembly condition, added necessary tolerances to the weldment setup, and corrected the installation process. The updated approach reduced rework from 80% to 5%.
Making the fix durable
Beyond the immediate correction, I developed quality and safety standards documents and presented the findings to manufacturing leadership, QC teams, and the production floor.