OPTIS boosts productivity by up to 155%

OPTIS boosts productivity by up to 155% for Plastic and Metal Manufacturer

OPTIS improved productivity by up to 155% for a leading manufacturer to OEMs within the industrial equipment industry.


OPTIS was also able to dramatically improve part quality, with a 90% reduction in scrap and reworking.

Jon Iverson, Chief Executive Officer at OPTIS, said: “The client needed to reassess equipment capability to meet the exacting quality standards their customers expect. Serving the medical, agricultural, construction and industrial sectors, they also needed to reduce costs for the especially competitive markets. Component quality, in particular, was a critical consideration, since end customers don’t accept any less than 100% of their part print requirements.”

After the molding process, each component required machining of both highly abrasive plastic and metallic materials. The components were machined on an older high volume dial index. LeanMachine™ was used to assess the condition of the equipment and report on its capability to meet the part’s specified requirements.

Onsite observations, combined with reported part quality data and the machine’s overall condition, lead to a recommendation to rebuild or replace the equipment for the manufacturing process, to meet quality demands.

After reviewing the quality and productivity of the machining process, data from each station’s cycle times, machine processes, cutting tools, workholding fixtures, functional inspection tooling and operator interface was used to redesign the dial index machining process. This generated a set of recommendations which would deliver significant improvements to the quality and productivity of the machine.

This analysis gave the company accurate data to build a solid business plan, justifying the investment in the equipment upgrade.
But more than that, the OPTIS experts noticed that there were other issues beyond the machine itself that were affecting quality too. As a result, OPTIS were able to offer and implement a detailed list of solutions including the change of the drill geometry to achieve better hole location; change of the taps to achieve better cutting and fewer burrs; implementation of work holding improvements to reduce changeover time; and rebalance the operations performed at each station to achieve better throughput.

LeanMachine™ technology employs proprietary analytic tools and data driven process analysis to look deep within customers’ machines, unlocking value by optimizing cost, improving quality and reducing cycle times for critical equipment.

Moreover, LeanMachine™ goes beyond analytics and theory, to take action on insights. Using advanced in-line probing, dynamometers and tool condition monitoring in OPTIS’ machining laboratory, the company even proves solutions before their implementation, completely removing risk and disruption for customers.