Defect Reduction at a Global Engine-Block and Cylinder-Head Manufacturer

A world-leading manufacturer of cast-iron engine blocks and cylinder heads improved defect rates by using advanced process-parameter optimisation across its molding, core-making, and pouring operations. By identifying high-impact controllable variables and guiding operators toward the optimal operating region, the foundry achieved sustained reductions in process-caused defects and strengthened line-to-line stability.

Mixing and Curing Optimisation at a Global Tyre Manufacturer

A global tyre producer improved six key rubber quality metrics by nearly 40% on average in its mixing and curing operations, reducing variability between lines and creating a template for scaling best-practice recipes across plants.

Multi-Plant Scrap Reduction at an Automotive and Industrial Cast-Iron Foundry Group

A multi-plant cast-iron foundry group used a single view of process and quality data to cut scrap on initial casting families by roughly 40% and establish a repeatable playbook for yield improvement across sites.

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Stud Weld Quality Improvement at a Global Automotive OEM

An automated body-in-white line at a global passenger-vehicle OEM reduced stud weld defects by more than half and saved an estimated $120k–$140k per month by standardising best-practice settings and stabilising its joining process.