Re-start/ Revamp of FAP (Fehlerabstellprozess)/ Failure Elimination Process

Project: Re-start/ Revamp of FAP (Fehlerabstellprozess) - Failure Elimination Process

What is FAP?
FAP is a structured approach for resolving systemic plant
issues escalated from Body, Paint, Assembly, Engine Shops,
and Quality Assurance. Managed by 8 Cross-Functional
Teams (CFTs), it uses a systematic problem-solving
methodology.

Key Improvements:
2013: Transferred FAP to Quality Planning, addressing
previous inefficiencies.
2014: Redefined FAP, introducing stricter pre-analysis,
timelines, escalation, and exit criteria.
Training: Conducted Six Sigma Mindset training for all CFT
leaders and members.
First-Ever FAP Budget: Enabled faster decision-making and
issue resolution.
Recognized by Volkswagen HQ and Typeleader Conference
for improved methodology.

Impact:
Strengthened problem resolution efficiency and reduced
production bottlenecks.
Successfully resolved 10 systemic issues and implemented
12 corrective measures within a year, significantly improving
plant quality performance.