DBW Polska focuses on the production of cutting-edge mineral wool and fiberglass goods, providing critical high-performance components. Operating within the unforgiving automotive industry, the company knows that even minor deviations can lead to massive expenses and customer production delays. DBW Polska's process stability and reliability are backed by an elite client roster featuring iconic names like Ferrari, BMW, and Volkswagen.

Solution

The process was initially organized using simple tables and swimlanes, precisely dividing responsibility among key departments, customers, and suppliers. DBW Polska implemented two-tier Layered Process Audits (LPA) in the auditomat® application — Layer 1 (detailed at the workstation level) and Layer 2 (global for the entire department). Full transparency of schedules was introduced, along with the requirement to document defect resolution using photos taken with a tablet or smartphone directly within the auditomat® system.

A systemic approach and audit data have led to a steady, visible decline over time in the number of recorded production non-conformities. The full integration of quality with logistics allows inspection schedules to be flexibly adjusted to machine downtime and maintenance without losing input data. The division into verification and self-improvement audits, combined with hard digital evidence, significantly facilitates passing certification audits and cooperating with demanding automotive clients.

Dividing audits into verification and self-improving ones ("Themis with a blindfold") ensured that detected anomalies stopped being treated as a punishment and instead became a valuable source of knowledge and an opportunity for the organization's permanent development. Uncompromising attention to quality and full transparency of corrective actions drastically increase the trust of demanding automotive customers such as Volkswagen, BMW, and Ferrari, strengthening DBW Polska's market position.

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