Company A was a medium sized company that had won a contract to build a very special part for on of the worlds leading HDD companies. What we saw upon our first visit was that the part had a cumulative yield of <10% and each lot was being rejected by their customer because of various issues with the incoming quality.

After working with Company A for ~ 1 month, their yield had been improved to 99+%. Why? We worked with the mold designer to improve the quality of the molded part, completely changed the process flow, recommended several changes in their facility and did some intense training.

The improved parts were not returned from their customer and they ended up getting the majority of the business and began to make money.