Opportunity for a confidential client
Initial Defect Rate: 50%
When Invetech took over production from a major contract manufacturer, our client asked us to significantly enhance product performance, yield and consistency at scale.
Invetech set out with a clear ambition: to lift the manufacturing process to industry-leading standards through a series of innovative design and process improvements.
Over the next three years, we meticulously transformed the production process, phase by phase—delivering substantial gains in yield, quality and reliability, and creating a robust platform for our client’s long-term growth.
Solution
Final Defect Rate: <1%
Thanks to Invetech’s methodical review and deep domain knowledge, we were able to identify the root cause in a critical, heat-intensive step of the process, where material performance under temperature was limiting overall quality.
Invetech embarked on a comprehensive redesign. The team selected a resilient, foam-based material engineered to withstand higher temperatures without compromising integrity. This became a pivotal improvement and the foundation for a broader optimisation program.
Over the next five years, Invetech systematically refined each production component and process step, continually pushing towards a near-zero defect goal.
This commitment paid off: by overhauling materials and processes, Invetech achieved a final defect rate of less than 1%, setting a new benchmark in product quality and delivering exceptional, reliable performance for our client.
