Challenge
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
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Analysed the thermodynamics of the process
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Identified a critical error in the process
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Recommended an appropriate low-cost remedy
Benefits
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Increased manufacturing yield to 85%
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6-months work saved several million pounds
