In manufacturing, small defects can cascade into major disruptions. McCain’s process relied on paper logs, unclear accountability, and no feedback loop for defect resolution. TribalScale co-designed and built a Digital Defect Handling (DDH) platform tailor-made for McCain’s operational rhythms. By mapping real-world workflows and digitizing defect visibility, assignment, and tracking, McCain achieved a dramatic 70% reduction in defect submissions—unlocking a new era of manufacturing visibility and continuous improvement.
Impact Delivered
Challenge
McCain's packaging and processing areas had no structured system to capture or share defects. Critical issues were slipping through due to:
Lack of visibility—operators didn’t know how to log defects or alert maintenance.
No ownership—defects lingered without clear assignees or follow-ups.
Continuous inefficiency—repeated issues resurfaced, frustrating operators and delaying production.
They needed a real-time, role-centric solution to bring transparency, accountability, and speed to defect resolution.
Solution
TribalScale partnered deeply through:
Domain-Driven Design & Event Storming sessions—immersive workshops that surfaced the “current state” (AS-IS) workflows and co-created a clear, consensus-based “future state” (TO-BE) model.
Role-aligned workflow design—each user (operator, supervisor, maintenance) saw and interacted only with relevant defect tickets.
Integration architecture—leveraged real-time data flows between SAP, Azure, and Microsoft Power Platform to ensure centralized defect tracking, notifications, and status updates.
Tools and Technologies Used:
Microsoft Azure
Microsoft Power Apps
Azure API
Power Platform
SAP Sync
Outcome
The DDH platform went beyond a digital tool—it became an operational backbone. Teams now resolve issues rapidly, gain insights into recurring defects, and fuel continuous improvement. For TribalScale, this success reinforced its role as a trusted, agile innovation partner capable of driving transformation through digital tools.
Why It Matters
In complex manufacturing, the speed and clarity of issue resolution define productivity. DDH converted manual friction into real-time clarity, accountability, and insight—redefining how operations run and ensuring McCain stays agile, efficient, and actionable.