Case Studies

Results that start on the floor

Every engagement begins with an operational problem and ends with a measurable outcome. These illustrative case studies reflect the types of challenges we solve and the approaches we take.

Battery Manufacturing

AI-Powered Quality Prediction for a Battery Manufacturer

Challenge

A lithium-ion battery manufacturer was experiencing a 4.2% defect rate in cell assembly, with quality issues only detected during end-of-line testing. Each scrapped cell represented significant material cost, and root cause analysis was manual and retroactive.

Approach

We analyzed eighteen months of production data across formation cycling, electrode coating, and environmental monitoring systems. The data lived in three separate systems with no integration layer.

Solution

We built a unified data pipeline connecting the MES, formation cycler databases, and environmental sensors. A gradient-boosted classification model was trained on historical production data to predict cell quality outcomes based on in-process parameters. The model runs on local infrastructure — no data leaves the facility.

Results

  • Defect prediction accuracy of 91% at the electrode coating stage
  • 2.8% reduction in scrap rate within the first production quarter
  • $1.2M estimated annual material cost savings
  • Root cause identification time reduced from days to hours

Aerospace & Defense

ERP Data Integration & BI Platform for an Aerospace Contractor

Challenge

A mid-size aerospace contract manufacturer operated QAD for production and Salesforce for customer management, with financial reporting in a separate legacy system. Monthly close took two weeks because data had to be manually reconciled across all three platforms.

Approach

We mapped the complete data flow from quote through shipment, identifying 47 manual data entry points and 12 recurring reconciliation failures between systems.

Solution

We designed a SQL Server data warehouse with automated ETL pipelines from QAD, Salesforce, and the legacy financial system. A Power BI reporting layer provides real-time dashboards for operations, finance, and executive leadership. All infrastructure is on-premise to meet ITAR requirements.

Results

  • Monthly close reduced from 12 days to 3 days
  • Eliminated 47 manual data entry touchpoints
  • Real-time production visibility across 3 product lines
  • Finance team reclaimed 60+ hours per month from manual reporting

Contract Manufacturing

Custom Production Tracking App Replacing Excel Workflows

Challenge

A precision machining shop tracked work orders, machine utilization, and delivery schedules across 14 Excel spreadsheets maintained by 6 different people. Version conflicts were daily, data was frequently lost, and customer delivery reporting was always two days behind.

Approach

We spent a week on the shop floor observing how each spreadsheet was actually used — who updated what, when, and why. Three of the fourteen spreadsheets turned out to be redundant.

Solution

We built a web-based production tracking application with role-based views for shop floor operators, supervisors, and front office staff. Barcode scanning for job tracking, real-time machine status dashboards, and automated customer delivery notifications. Deployed on the company's local network with a mobile-friendly interface for the shop floor.

Results

  • Order status visibility went from 2-day lag to real-time
  • 14 spreadsheets consolidated into a single application
  • On-time delivery tracking accuracy improved from 82% to 97%
  • New employee onboarding time for production tracking reduced by 70%

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