Quality Reclaimed Through XO Dynamic Learning

Background:

A global Tier 1 automotive supplier was struggling with chronic reliability issues at its heat exchanger plant in Mexico. Despite ongoing internal efforts, several high-cost defects continued to undermine product performance, drive customer complaints, and strain plant resources. Crossover Solutions was brought in to lead an on-site Dynamic Learning™ Workshop to build internal capability, accelerate root cause identification, and restore control.

 

Critical Issues:

• High internal scrap costs and test failures
• High customer complaints

Approach:

Crossover Solutions deployed our expert-led Dynamic Learning model to build internal diagnostic capability and accelerate resolution of chronic failures. Over two days, 20 plant engineers and technicians were immersed in first-principles thinking, system behavior analysis, and convergent diagnostics.

Key Actions:

We structured the engagement into four focused teams, each tackling one of the top 4 production problems using hands-on application of the method to isolate true causes. Teams worked directly on the shop floor, generating real-time causal explanations to guide corrective actions by applying the key steps of XO’s Dynamic Learning™ to all 4 problems.

• Cartooning
• Characterization
• Display and interpretation of results
• Further Convergence
• Identify Causal Explanation

Results:

Through the XO Dynamic Learning™ workshop, all chronic quality issues were resolved through precise, first-principles diagnostics. Teams developed clear causal explanations, implemented corrective actions, and validated improvements in live production.

• Causal Explanation identified for all top 4 problems, accounting for more than 80% of scrap and customer complaints.
• Teams left with strengthened diagnostic capability, shifting the plant culture from reactive troubleshooting to proactive prevention