A manufacturing process required that at least 99.75% of the products be defect free. Products were batched for testing. If too many defects were found then the entire batch had to be rejected. At the start of the project, more than half of the manufactured product was unsaleable.
What We Did
Analysed the thermodynamics of the process
Identified a critical error in the process
Recommended an appropriate low-cost remedy
Increased manufacturing yield to 85%
6-months work saved several million pounds
Gremlins In Your Manufacturing Process?