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Case Studies

How manufacturers use Zometric to lift quality, cut scrap, and stabilize their lines.

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Results, not slideware.

Two recent deployments. The KPIs are real, the modules are named, the challenges sound like yours.

Automotive· In-Process Quality & SPC

Automotive supplier wins new OEM business with verifiable process control

90%Reduction in PPM levels

NewOEM business won

↓Scrap & rework cost

↑Productivity (fewer stoppages)

Challenge

Needed to demonstrate that every CTQ characteristic was consistently in statistical control to secure new OEM business. Could not prove this with a manual, paper-based system.

Solution

In-Process Quality & SPC deployed with manual plus automated data capture on the shopfloor. Automated SPC identified process instabilities in real time. Control charts, capability indices and Nelson's-rules violations tracked digitally.

Automotive· Production Management

Auto component manufacturer cuts downtime by 40% without replacing equipment

40%Reduction in downtime

Real-timeAlerts activated

↑Operator accountability

↓Recurring issue rate

Challenge

Frequent, costly downtime losses. Machines had no data transmission. Manual downtime logs were unreliable. Management had no visibility into real causes or patterns.

Solution

Production Management deployed with a custom retrofit device converting electrical signals into digital data — enabling automated downtime tracking without replacing any existing equipment. Operators logged causes on tablets. Alerting triggered real-time email notifications to relevant teams.

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