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.
