Week two: the human factor.
Practical tip: formalize post-mortems into living documents—include hypotheses tested, data visualizations, and the exact sequence of mitigations with measured outcomes.
Week one: the tolerance variance.
Week five: the validation.
They didn’t overhaul the line in one dramatic sweep. Instead, they layered mitigations. HVAC setpoints were tightened for targeted zones during night shifts. The polishing compound was replaced after a compatibility matrix flagged the reactive interaction. Jonah’s nights were rotated for cross-training and to decouple human rhythm from process sensitivity. A statistical process control (SPC) dashboard was pushed to the monitors, with real-time alarms mapped to specific tolerances and root-cause histories accessible at two clicks.