Services

Engineering-led problem solving that delivers measurable quality improvement

 

Goring Engineering Consultancy helps manufacturing and engineering organisations solve complex quality, process and production problems using practical, proven improvement methods. Drawing on more than 40 years of manufacturing, quality, electronics, mechanical engineering, Lean, Six Sigma, IPC, supplier quality, metrology and process improvement experience, we support clients who need rapid containment, robust root cause analysis, sustainable corrective action and measurable performance improvement.

We do not simply explain quality tools in theory. We help organisations apply the right method to the right problem, using real production evidence, shop-floor investigation, team facilitation, data analysis and clear action planning. Whether the challenge is a customer complaint, recurring defect, supplier issue, inspection inconsistency, process instability, capability shortfall or production inefficiency, Goring Engineering provides practical support that turns problems into controlled, repeatable and improved processes.

Our approach is built around clear diagnosis, disciplined investigation, evidence-based decision-making and sustainable implementation. We help clients reduce repeat defects, improve first-time pass rates, protect customer confidence, improve audit readiness, reduce waste and build internal capability.

 

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8D Problem Solving

Permanent Solutions to Complex Manufacturing Problems

 

8D (Eight Disciplines) is a structured problem-solving methodology used to identify, contain, investigate and permanently eliminate recurring problems. Originally developed by Ford Motor Company, it is now recognised worldwide across automotive, aerospace, electronics, medical devices and precision engineering.

Unlike simply fixing symptoms, 8D focuses on identifying the true root cause, implementing corrective actions, verifying their effectiveness and preventing recurrence.

 

How Goring Engineering Delivers This

Goring Engineering supports 8D investigations by helping clients form the right cross-functional team, define the problem clearly, contain the issue quickly, identify escape points, verify root cause, implement corrective actions and confirm that recurrence has been prevented. We can lead or coach the full 8D process, prepare customer-facing responses, support supplier quality investigations and help embed lessons learned into procedures, controls, training and audit evidence.

 

How 8D Helps Your Organisation

A disciplined 8D process enables organisations to:

• Resolve customer complaints effectively 

• Reduce recurring defects 

• Improve customer confidence 

• Meet supplier quality requirements 

• Strengthen quality management systems 

• Capture organisational learning 

• Improve cross-functional teamwork 

 

Typical Applications

• Customer returns 

• Supplier quality issues 

• Warranty failures 

• Manufacturing defects 

• Product failures 

• Field service investigations 

• Regulatory compliance 

 

Example

An electronics manufacturer experienced repeated solder joint failures during environmental testing. Goring Engineering-style support would focus first on containment and risk to the customer, then investigate process inputs such as solder profile, materials, operator technique, inspection criteria and environmental controls. Once the incorrect reflow profile and weak process controls were identified, corrective actions would include revised process parameters, operator retraining, verification checks and ongoing monitoring to prevent recurrence.

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PDCA (Plan – Do – Check – Act)

A Proven Framework for Continuous Improvement

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The Plan-Do-Check-Act (PDCA) cycle, developed by Dr. W. Edwards Deming, provides a structured approach for testing improvements before implementing them across an organisation.

Rather than making large-scale changes based on assumptions, PDCA encourages small, measurable improvements that are evaluated before becoming standard practice.

 

How Goring Engineering Delivers This

Goring Engineering uses PDCA to help clients test improvements in a controlled, low-risk way before full implementation. We help define the improvement objective, agree practical measures, run small-scale trials, evaluate results and standardise what works. This is particularly valuable where production teams need to improve output, quality, safety, layout, maintenance routines or working methods without disrupting day-to-day operations.

 

How PDCA Helps Your Organisation

 

PDCA helps businesses:

• Reduce implementation risks 

• Improve process stability 

• Encourage continuous improvement 

• Support Lean Manufacturing 

• Improve decision making 

• Standardise successful improvements 

• Build a culture of learning 

 

Typical Applications

• Manufacturing improvements 

• Production process optimisation 

• Quality improvements 

• Engineering projects 

• Maintenance improvements 

• New procedures 

• Continuous improvement programmes 

 

Example

A production cell experiencing inconsistent output used PDCA to trial revised work instructions and workstation layout changes. A Goring Engineering-led approach would define the baseline performance, test the revised method with operators, check output and defect data, and then standardise the improved layout only after the evidence confirmed it worked.

 

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A3 Problem Solving

Structured Thinking for Better Decisions

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The A3 methodology is a Lean problem-solving and communication tool that captures an entire improvement project on a single A3-sized sheet of paper. Rather than creating lengthy reports, it encourages clear thinking, logical analysis and collaborative decision-making.

An A3 document typically includes the problem statement, current condition, root cause analysis, proposed countermeasures, implementation plan and follow-up actions.

 

How Goring Engineering Delivers This

Goring Engineering uses A3 problem solving to turn complex issues into clear, visual and manageable improvement plans. We help teams define the current condition, quantify the gap, identify root causes, agree countermeasures and communicate progress clearly to stakeholders. This is especially useful when leadership teams need concise visibility of an issue without losing the detail required for robust problem solving.

 

How A3 Problem Solving Helps Your Organisation

 

A3 Problem Solving enables organisations to:

• Improve structured thinking 

• Standardise problem-solving methods 

• Encourage collaboration 

• Develop leadership capability 

• Improve communication 

• Support continuous improvement 

• Create documented organisational learning 

 

Example

An engineering team experiencing repeated machining delays used an A3 to identify inconsistent tooling preparation and unclear ownership as key causes. Goring Engineering would support the team by mapping the current condition, validating the delay data, agreeing countermeasures and helping standardise tool preparation so the improvement becomes part of everyday working practice.

 

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Root Cause Analysis (5 Whys)

Solving Problems at Their Source

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The 5 Whys is a simple but highly effective Root Cause Analysis technique that identifies why problems occur by repeatedly asking the question "Why?" until the underlying cause is found.

Rather than addressing symptoms, this approach identifies the process failures that allowed the problem to occur.

 

How Goring Engineering Delivers This

Goring Engineering facilitates 5 Whys investigations to prevent teams from stopping at the first obvious cause. We challenge assumptions, test each “why” against evidence and ensure the final root cause leads to a practical corrective action. Where the issue is more complex, we combine 5 Whys with Fishbone analysis, 8D, CAPA or process data to make sure the investigation is robust enough for the risk involved.

 

How 5 Whys Root Cause Analysis Helps Your Organisation

 

The 5 Whys helps organisations:

• Eliminate recurring defects 

• Improve quality 

• Reduce downtime 

• Improve maintenance 

• Reduce customer complaints 

• Strengthen corrective actions 

• Improve operational learning 

 

Example Problem:
Machine stopped unexpectedly.

Why?
A bearing failed.

Why?
Lubrication was insufficient.

Why?
Lubrication schedule was missed.

Why?
Maintenance planning system wasn't updated.

Why?
Responsibility had not been assigned after organisational changes.

 

The permanent solution was not simply to replace the bearing. It was to restore ownership of the maintenance process, update the planning system, verify lubrication compliance and prevent the same failure mode from returning.

 

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CAPA (Corrective and Preventive Action)

Preventing Problems Before They Return

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CAPA is a systematic approach used to investigate quality issues, identify root causes and implement both corrective and preventive actions.

Corrective Actions eliminate existing problems.

Preventive Actions remove conditions that could cause future problems.

CAPA forms a core requirement within ISO 9001, ISO 13485, AS9100 and many regulated industries.

 

How Goring Engineering Delivers This

Goring Engineering helps clients build CAPA actions that are specific, evidence-based and auditable. We support issue definition, root cause analysis, corrective action planning, preventive action planning, effectiveness checks and closure evidence. This helps organisations move beyond temporary fixes and demonstrate to customers, auditors and internal leaders that problems have been properly understood and controlled.

 

How CAPA Helps Your Organisation

Effective CAPA systems:

• Reduce recurring issues 

• Improve compliance 

• Strengthen quality systems 

• Improve customer satisfaction 

• Reduce warranty costs 

• Improve supplier performance 

• Support continual improvement 

 

Example

Following repeated customer complaints regarding dimensional variation, CAPA identified worn tooling, weak inspection frequency and insufficient process monitoring. Goring Engineering would support the client by linking the corrective actions to verified root causes, introducing preventive controls such as planned tooling checks and revised inspection routines, and confirming effectiveness through follow-up performance data.

 

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Poka-Yoke (Mistake Proofing)

Designing Processes That Prevent Human Error

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Poka-Yoke, meaning "mistake proofing" in Japanese, involves designing products, fixtures and processes so that errors become impossible—or immediately obvious before defects occur.

Rather than relying solely on inspection, Poka-Yoke prevents mistakes from entering the process.

 

How Goring Engineering Delivers This

Goring Engineering helps clients identify where human error, unclear process design or weak controls allow defects to occur. We then work with engineering, production and quality teams to design practical mistake-proofing solutions such as fixtures, visual controls, sensors, interlocks, check methods, barcode validation or standardised work. The goal is to make the right action easy and the wrong action difficult or impossible.

 

Typical Examples

• Parts that only fit one way 

• Sensor verification 

• Barcode validation 

• Connector keying 

• Assembly fixtures 

• Interlocks 

• Software validation prompts 

How Poka-Yoke Helps Your Organisation

Poka-Yoke helps organisations:

• Reduce defects 

• Improve product quality 

• Reduce rework 

• Improve safety 

• Increase productivity 

• Reduce inspection requirements 

• Improve customer satisfaction 

 

Example

An assembly fixture was redesigned so that a component could only be inserted in the correct orientation. A Goring Engineering-led review would also check whether the solution is robust, easy to use, maintainable and supported by operator training and standard work, helping prevent the error from returning as volumes, people or product variants change.

 

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Ishikawa (Fishbone) Diagrams

Understanding Every Possible Cause

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The Ishikawa Diagram, also known as a Fishbone or Cause-and-Effect Diagram, helps teams systematically identify every potential cause contributing to a problem.

Rather than focusing on obvious issues, the method encourages structured investigation across multiple categories.

 

How Goring Engineering Delivers This

Goring Engineering uses Fishbone analysis to structure team investigation and ensure important causes are not missed. We facilitate the discussion across people, process, equipment, material, measurement and environment, then help prioritise which potential causes need evidence, testing or elimination. This avoids opinion-led problem solving and supports stronger 8D, CAPA and continuous improvement outcomes.

 

Typical categories include:

• People 

• Machines 

• Methods 

• Materials 

• Measurement 

• Environment 

 

How Fishbone Analysis Helps Your Organisation

Fishbone analysis:

• Encourages team collaboration 

• Supports Root Cause Analysis 

• Identifies hidden causes 

• Prevents assumptions 

• Improves investigation quality 

• Supports CAPA and 8D investigations 

 

Example

Investigating excessive solder defects identified several contributing factors, including humidity, operator technique, solder paste storage and stencil cleaning frequency. Goring Engineering would help separate likely causes from assumptions, prioritise evidence gathering and convert confirmed causes into practical controls that improve yield and consistency.

 

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Measurement Systems Analysis (MSA)

Ensuring You Can Trust Your Measurement Data

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Measurement Systems Analysis (MSA) evaluates whether measurement equipment and inspection methods are capable of producing reliable, repeatable and accurate data.

If measurements cannot be trusted, improvement decisions cannot be trusted either.

 

How Goring Engineering Delivers This

Goring Engineering helps clients assess whether inspection and measurement systems are suitable for the decisions being made from them. We review measurement methods, equipment suitability, operator technique, calibration status, inspection standards and data consistency. This is particularly important where customers challenge results, inspectors disagree, process capability is unclear or false rejects and false accepts are affecting cost and confidence.

 

MSA Evaluates

• Accuracy 

• Precision 

• Repeatability 

• Reproducibility 

• Stability 

• Linearity 

• Bias 

How MSA Helps Your Organisation

MSA helps organisations:

• Improve inspection confidence 

• Reduce false rejects 

• Reduce false accepts 

• Improve process capability studies 

• Meet customer requirements 

• Support Six Sigma projects 

 

Example

MSA identified excessive variation between inspectors using digital callipers. Goring Engineering would support the client by reviewing the measurement method, standardising the technique, training inspectors against agreed criteria and confirming improvement with follow-up measurement data.

 

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Process Capability

Measuring Whether Your Process Can Consistently Meet Specification

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Process Capability measures how consistently a manufacturing process produces output within customer specification limits.

Common capability indices include:

• Cp 

• Cpk 

• Pp 

• Ppk 

 

Higher capability values indicate greater process stability and lower defect risk.

 

How Goring Engineering Delivers This

Goring Engineering supports process capability studies by helping clients confirm that the process is stable, the measurement system is reliable and the data is suitable before capability is calculated. We help interpret Cp, Cpk, Pp and Ppk results in practical business terms, linking the analysis to scrap reduction, customer risk, inspection strategy, process control and improvement priorities.

 

How Process Capability Helps Your Organisation

Process Capability studies help organisations:

• Predict defect levels 

• Improve quality 

• Reduce scrap 

• Reduce inspection 

• Improve customer confidence 

• Support continuous improvement 

 

Example

Capability analysis identified a machining process operating at Cpk 0.82. Goring Engineering would help determine whether the issue was centring, variation, tooling, method, material or measurement related, then support practical improvement actions. Following tooling improvements and process optimisation, capability increased to Cpk 1.67, reducing customer rejects and strengthening confidence in the process.

 

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Gauge Repeatability & Reproducibility (Gauge R&R)

Measuring the Measurement Process

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Gauge R&R is one of the most important components of Measurement Systems Analysis.

It evaluates whether measurement variation comes from.

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How Goring Engineering Delivers This

Goring Engineering uses Gauge R&R to help clients understand whether measurement variation is coming from the gauge, the operator, the method or the parts themselves. We help plan the study, select representative parts and operators, interpret the results and convert findings into practical actions such as gauge improvement, fixture changes, inspection method updates or inspector training.

 

• The measuring equipment (Repeatability) 

• Different operators (Reproducibility) 

 

How Gauge R&R Helps Your Organisation

 

Gauge R&R helps organisations:

• Improve inspection reliability 

• Reduce variation 

• Improve customer confidence 

• Validate measurement systems 

• Support PPAP submissions 

• Improve quality decisions 

 

Example

A Gauge R&R study found that 35% of measurement variation came from inconsistent operator technique. Goring Engineering would help standardise the measurement method, train inspectors, confirm repeatability and reproducibility, and ensure future quality decisions are based on reliable measurement data.

 

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Design of Experiments (DOE)

Finding the Best Process Through Scientific Experimentation

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Design of Experiments (DOE) is a statistical methodology that investigates how multiple process variables interact and influence product performance.

Unlike changing one variable at a time, DOE evaluates several factors simultaneously, dramatically reducing development time while improving understanding.

How Goring Engineering Delivers This

Goring Engineering helps clients use DOE when process performance depends on several interacting variables and trial-and-error improvement is too slow or unreliable. We support experiment planning, factor selection, response measurement, trial discipline, data interpretation and practical implementation. This helps clients optimise settings, reduce variation and build a deeper understanding of how their process really behaves.

 

Typical Variables

• Temperature 

• Pressure 

• Speed 

• Feed rate 

• Time 

• Material type 

• Solder profile 

• Tool geometry 

How DOE Helps Your Organisation

DOE enables organisations to:

• Optimise manufacturing processes 

• Reduce development time 

• Improve yields 

• Reduce variation 

• Improve robustness 

• Support Six Sigma projects 

• Reduce production costs 

 

Example

Using a fractional factorial DOE, an electronics manufacturer identified the optimum solder reflow profile, improving first-pass yield while reducing process variation. Goring Engineering would help define the key input variables, design the experiment, interpret the results and translate the findings into stable process settings, operator guidance and monitoring controls.

 

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ANOVA (Analysis of Variance)

Making Data-Driven Decisions with Statistical Confidence

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Analysis of Variance (ANOVA) is a statistical technique used to determine whether differences between groups are statistically significant or simply the result of natural variation. It is widely used in manufacturing, engineering, product development and quality improvement to validate changes and support evidence-based decision-making.

ANOVA is particularly valuable when comparing three or more groups, such as different machines, operators, suppliers, materials or process settings. Rather than relying on opinion or visual inspection of data, ANOVA provides confidence that observed differences are genuine.

 

How Goring Engineering Delivers This

Goring Engineering uses ANOVA to help clients make confident decisions when comparing machines, operators, suppliers, materials or process settings. We help ensure the data is suitable, explain the statistical result in plain English and connect the conclusion to practical engineering action. This prevents teams from overreacting to normal variation or missing a genuinely significant performance difference.

 

How ANOVA Helps Your Organisation

 

ANOVA supports organisations by:

• Validating process improvement initiatives 

• Comparing machine or production line performance 

• Assessing supplier variation 

• Evaluating operator consistency 

• Identifying significant process variables 

• Supporting Design of Experiments (DOE) 

• Reducing unnecessary process adjustments 

 

Typical Applications

• Comparing production lines 

• Evaluating different raw material suppliers 

• Machine capability studies 

• Heat treatment validation 

• Process optimisation 

• Product development trials 

• Six Sigma improvement projects 

 

Example

A precision engineering company compared dimensional variation across four CNC machining centres. While average measurements appeared similar, ANOVA confirmed that one machine produced significantly greater variation. Goring Engineering would help validate the data, interpret the result and guide the follow-up investigation. In this case, spindle wear was identified and corrective maintenance restored consistent process performance while reducing scrap and rework.

 

Choosing the Right Problem-Solving Method

Not every quality problem needs the same tool. Goring Engineering helps clients select the right approach based on risk, complexity, urgency and available evidence.

For immediate customer issues and repeat defects, 8D is often the strongest framework because it combines containment, investigation, corrective action and recurrence prevention.

For controlled improvement trials, PDCA is useful because it allows teams to test changes before full deployment.

For concise communication and leadership visibility, A3 problem solving provides a clear structure that keeps the issue, evidence and action plan together.

For simple cause-and-effect questioning, 5 Whys can be effective, but for more complex or multi-factor problems, Fishbone analysis, 8D or CAPA may be needed.

For regulated, customer-facing or audit-sensitive issues, CAPA provides the discipline required to demonstrate corrective and preventive action with evidence.

For measurement-related uncertainty, MSA and Gauge R&R should be considered before making decisions based on inspection data.

For capability concerns, process capability analysis helps confirm whether a process can reliably meet specification.

For complex optimisation, DOE and ANOVA support data-driven decisions where several variables, settings or groups need to be compared.

The value comes not from using every tool, but from using the right tool well. Goring Engineering brings the experience to decide what is proportionate, practical and effective.

 

How Goring Engineering Can Help

If you are dealing with recurring defects, customer complaints, supplier quality issues, unstable processes, inspection disagreement, poor capability or improvement projects that are not delivering results, Goring Engineering Consultancy can help.

We can parachute in as a practical Lean, continuous improvement, quality engineering or process improvement specialist, working alongside your team to diagnose the issue, select the right tools, lead the investigation, implement corrective actions and leave behind stronger processes and improved capability.

Support can include facilitated workshops, 8D investigations, CAPA support, process mapping, measurement studies, capability analysis, supplier quality support, Lean improvement activity, bespoke training and mentoring for engineers, operators, quality teams and leaders.

Get in touch to discuss the problem, the business impact and the level of support required.