Reduction in Quality Costs
We measurably reduce your quality costs – through efficient processes, error prevention and consistent elimination of causes.
Improve quality, avoid losses, increase profitability
Create transparency about error costs and reduce them sustainably through targeted measures.
- Your quality costs are rising - but the product quality remains the same?
- Rework, rejects, inspection work and complaints cause high internal costs?
- You don't know where the real cost drivers in your company are in the area of quality?
Many companies lack reliable data on the actual costs of errors, inspections and quality activities. Quality is practiced – but often inefficiently, expensively and reactively.
T.A.S. FORCE supports companies in systematically analyzing their Total Cost of Quality (TCoQ), breaking it down into direct cost drivers and significantly reducing it through structured measures – while at the same time improving product quality and increasing customer satisfaction.
Our core services for reducing quality costs
Creating transparency - Where do your quality costs really arise?
- Recording the current quality cost structure along the entire value stream
- Differentiation between internal defect costs, external defect costs, inspection costs and prevention costs
- Analysis of typical cost drivers: rework, rejects, sorting campaigns, external complaints, warranty costs
- Definition of key figures and dashboards, e.g. ppm, cost of poor quality (COPQ), COQ/production value
- Establishment of regular Q-cost reporting for control at management level
Only those who know where the losses occur can eliminate them sustainably.
Reduce error costs - eliminate causes instead of symptoms
- Analysis of the most common causes of errors in production, assembly, logistics and at the supplier
- Introduction of a structured root cause approach for sustainable remediation (e.g. 5-Why, Ishikawa, A3)
- Evaluation of the economic damage per type of error to prioritize the measures
- Establishment of company-wide error cost management with clear responsibilities
- Integration into existing QM systems (e.g. 8D, store floor, lean methods, PDCA cycles)
We combine methodological expertise with a business management focus – for measurable savings.
Optimize inspection costs & inspection intensities
- Analysis of inspection plans, sampling systems and quality control loops
- Identification of redundant or inefficient testing processes
- Shift from end-of-line inspections to process-integrated quality inspections
- Introduction of risk-based testing concepts (e.g. AOQ, Poka Yoke, SPC)
- Digital inspection management: CAQ systems, automated evaluation, test equipment utilization
Testing costs – avoidance saves. We help you to realign your testing concept economically.
Cost-optimized control of requalifications & complaints
- Efficient control of requalifications, special releases & restarts
- Standardization of complaint processing incl. 8D, 5D, action tracking
- Establishment of cost monitoring for external complaints & warranties
- Use of lessons learned to avoid recurring complaint costs
- Training & coaching for fast, efficient processing of customer and supplier complaints
Acting quickly not only saves trouble – it also saves money.
Improve supplier quality & reduce external error costs
- Analysis of supplier errors, ppm development & audit deviations
- Development of supplier Q-indicators & risk clustering
- Implementation of a systematic supplier development program to reduce external error costs
- Implementation of Q-workshops & process analyses at the supplier's premises
- Anchoring of Q specifications in supplier contracts, approvals & escalation mechanisms
Good quality starts with the supplier – we help to minimize the costs of external errors.
Profitability assessment & business case per measure
- Prioritization of measures according to economic benefit (cost/benefit analysis)
- Development of a Q-cost optimization program with defined savings targets
- Integration of the measures into Q controlling & target agreements
- Introduction of key figures for performance evaluation (return on quality)
- Support with the internal business case to legitimize the optimization projects
Quality management should not be an end in itself – we show how it can be economically effective.
Track record: quality costs reduced, quality increased
- Reduction of error costs by30% within 12 months through targeted measures
- 20% lower inspection costs thanks to new inspection strategies & digitalization approaches
- Reduction of external complaint costs by40% through supplier development program
- Reworkreduced by 50% through root cause elimination & more robust processes
- Cost-benefit ratio of optimization measures averages 1:4
FAQ - Frequently asked questions
"Why T.A.S. FORCE?" Your questions, our answers
Why T.A.S. FORCE for your quality cost optimization?
- Business-based approach – we turn quality into a measurable value driver
- Clear link between quality and profitability
- Operational implementation with measurable results – no PowerPoint concepts
- Experience from over 200 projects in automotive, mechanical engineering, MedTech & more
- Interface between the worlds of quality, production and finance – we understand all three languages
When should you optimize your quality costs?
- Your Q costs increase, but the result does not improve
- Error costs & rework block resources and budget
- You need reliable quality figures in euros – not just in ppm
- Testing efforts are too high – or too ineffective
- You are looking for economically viable Q solutions to improve results