Build a One-Page A3 for Repeat Repairs
Apply A3 problem solving to an aftersales operating problem.
Repeat repairs on Model Q compressors increased from 7% to 12% across three branches in four weeks. A3 problem solving The common trap is jumping from complaint to remedy without measuring the process condition that produced it. Background Define the business and customer impact: 41 repeat visits, 18 escalations, and 312 lost service hours. A3 starts with shared context so the team does not debate anecdotes. Current condition Segment repeats by model, branch, technician, part, and symptom. The pattern shows 68% of repeats involve one pressure sensor installed during first repair. Root cause Trace installation steps and find the torque…
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