A key element of any quality management system is continuous improvement and a systematic approach to managing non-conformances. The aim of this paper is to use selected statistical methods and quality control techniques to present a way in which an organisation can achieve quality improvement. The 8D methodology was used to solve the observed front grid problem on the bumper of a Porsche Cayenne using a structured eight-step Plan-Do-Check-Act (PDCA) approach to problem solving. As this was an important customer originating from Dubai, it was imperative to immediately start solving the issue that arose with the ACC grid on the front bumper, the problem identified was an existing cut-out in the radar grid. Using the 8D methodology and supporting tools such as the Ishikawa diagram or 5Why, the root cause of the problem was identified and permanent corrective actions were planned and implemented as recommended in the 8D report to reduce the likelihood of the problem recurring and increase customer satisfaction.
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