Case Studies

3.5 Weeks Past the Deadline: How a Special-Purpose Machinery Manufacturer Mastered Penalty-Free Deliveries

Lean · 3 min read · 26.08.2026

Client A machine-building company manufacturing custom special-purpose machines — welding, testing and assembly equipment for industrial customers. 85 employees, one shift, supplemented by on-site assembly call-outs at customer facilities.…

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40 % Repeat Complaints: How an Automotive Tier 2 Supplier Stopped Closing 8Ds on Paper

Quality · 3 min read · 19.08.2026

How we helped an automotive Tier 2 supplier of welded assemblies, where 8D reports closed purely as a formality were leading to 40 % repeat complaints and a threat of CS2 escalation from the OEM customer.

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Changeover from 45 to 12 Minutes: How an Engineering Company Cut Costs Without Layoffs

Costs · 4 min read · 29.07.2026

An engineering company with 240 employees was losing margin on small batches — long changeovers, overtime and a 4.2% scrap rate. The project paid for itself in five months: changeover time fell to 12 minutes and scrap dropped by 38%.

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21 of 28 8D reports blamed the operator: how an automotive welding plant found the real causes

Quality · 3 min read · 19.08.2026

As many as 21 of 28 closed 8D reports in the welding plant blamed the operator. In an audit we uncovered three systemic failures of the method and introduced a rule: a cause is only proven when we can deliberately trigger it and suppress it.

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Reducing Recurring Defects from 40%: How an Automotive Supplier Stopped OEM Complaints

Quality · 3 min read · 12.08.2026

An automotive industry case study. We will show you how we reduced the rate of recurring defects from 40% by restructuring the 8D processes right on the shop floor.

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