Advanced Manufacturing / Electronics (PCB)
Production Yield & Quality Automation
15% Increase in First-Pass Production Yield
Eliminating paper-based shop floor scrap tracking with automated reject/rework analytics to catch manufacturing defects in real time.
The Challenge
An electronics component manufacturer was facing unpredictable drop-offs in production yield. Line operators tracked defects and component reworks manually on physical log sheets, which were compiled into Excel only at the end of the week. Because quality control data was purely historical, systemic machinery errors or component defects were caught days after they occurred, resulting in high scrap volumes, expensive reworks, and missed dispatch deadlines.
The Solution
CurveFore deployed an operational metrics dashboard directly linked to shop floor testing equipment and production logs.
Real-Time Defect Isolation: Engineered a reject-rework tracking module that categorizes defects by machine line, shift, and error type instantly.
Live Yield Analytics: Created a unified executive view displaying rolling first-pass yield metrics against daily production targets.
Early Warning Flags: Programmed statistical threshold alerts that ping production managers via automated workflows the moment a line's reject rate breaches a safe operational limit.
The Measurable Results
Metric Checked | Before CurveFore | With CurveFore | Business Impact |
|---|---|---|---|
Manual Tracking Overhead | 12 Hours/Week compiling sheets | 0 Hours (Fully Automated) | Staff redirected to line calibration |
First-Pass Yield (FPY) | Volatile / Sub-optimal | Increased by 15% | Drastic drop in total scrap waste |
Defect Detection Time | 3 to 5 Days Late | Instantaneous (Real-Time) | Stopped bad batches immediately |
Payback
Achieved in 4 Months
Metrics Checked
Manual Tracking Overhead
Before CurveFore
12 Hours/Week compiling sheets
With CurveFore
0 Hours (Fully Automated)
Business Impact
Staff redirected to line calibration
Metrics Checked
First-Pass Yield (FPY)
Before CurveFore
Volatile / Sub-optimal
With CurveFore
Increased by 15%
Business Impact
Drastic drop in total scrap waste
Metrics Checked
Defect Detection Time
Before CurveFore
3 to 5 Days Late
With CurveFore
Instantaneous (Real-Time)
Business Impact
Stopped bad batches immediately