Latest / The Operations Podcast with Fexingo: Process, People, and Profit in Modern Business
How a German Auto Plant Cut Rework by 90 Percent
Lucas and Luna dive into the operations story behind a German automotive plant that reduced rework costs by 90 percent over three years. The episode anchors on a single detailed case: a BMW component factory in Dingolfing that used poka-yoke (mistake-proofing) devices, real-time error tracking, and a worker-led continuous improvement protocol to slash defect rates from 3,200 parts per million to under 300. Lucas explains how the plant embedded quality checks directly into assembly line tools, so operators couldn't proceed if a step was missed. Luna challenges whether this approach scales…
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