Improving Yield from 60% to 98% in Aerospace Castings

An aerospace company in Southern California was experiencing a 40% scrap rate due to defects in investment castings supplied by a Wisconsin-based casting company, leading to production delays and frustration. Over five weeks, we worked to systematically identify the root causes of the problem, including issues with inspection processes, manufacturing methods, die design, and procurement practices. By implementing targeted improvements in each area and monitoring the changes, we were able to address the underlying issues effectively.

As a result, the first pass yield improved significantly to 98%, allowing the production line to get back on track. This focused approach resolved key challenges in a short time frame, improving operational efficiency and reducing waste.

Eliminating Pitting: Boosting Yield from 65% to 100% in Aluminum Aerospace Parts

An aerospace supplier in Southern California faced a persistent issue with NDT (non-destructive testing) indications on 7075 aluminum parts after anodizing by a special processes supplier in Arizona. This problem, which had persisted for over five years, caused a 35% scrap rate on a costly product, strained customer-supplier relationships, and resulted in significant financial losses.

In less than four weeks, we led an effort to identify the root cause within the supply chain, tracing the issue to earlier steps in the manufacturing process. By modifying and optimizing these processes, we completely eliminated the defect. It has now been over three years without a single recurrence of this issue, demonstrating the lasting impact of the solution and restoring confidence and efficiency in the supply chain.

Eliminating Chrome Defects: Reducing Scrap from 40% to 0% in Eight Weeks

A supplier in Southern California faced a long-standing challenge with electroplated chrome defects, which had persisted for over five years. Inspection after grinding frequently revealed small pinholes and larger defects on the chrome, leading to an average scrap rate of 40%. The issue was unpredictable, coming and going over time, but reached a critical point when the scrap rate escalated, causing production line downtime. The supplier turned to us for help during this crisis. Through a design of experiment and thorough Gemba walk, we identified two distinct root causes: pinholes stemming from an uncontrolled and undocumented change in the pre-chrome plating process, and larger defects resulting from a post-chrome grinding process, before the final inspection.

Within just eight weeks in 2023, we implemented robust improvement plans, including process modifications, documentation updates, and personnel training to ensure consistency. Our team worked closely with the supplier to stabilize their operations and monitor progress, eliminating the defects and preventing recurrence. Since the corrective actions were completed, the supplier has maintained a defect-free process, significantly reducing scrap rates and restoring production efficiency. This collaboration not only resolved a five-year problem but also reinforced the supplier’s ability to sustain quality in the long term.

Our expertise is focused on solving complex operational challenges that affect quality, efficiency, and productivity. We combine deep knowledge in process engineering, science, and metallurgy with proven methodologies such as DMAIC, 8D problem solving, Failure Mode and Effect Analysis (FMEA), Design of Experiment (DOE), and statistical analysis to develop tailored solutions that deliver measurable and lasting results. Whether it’s reducing defects, stabilizing processes, or improving production efficiency, we pair technical expertise with hands-on collaboration to drive impactful improvements. The success stories below are just a few examples of how we’ve helped organizations overcome challenges, and we are ready to partner with you to achieve your operational and quality goals.