Case Study: Ford Motor Company achieves 90%+ automated stamping process selection and increased First-Time-Through rates with Altair Knowledge Studio

Altair® Knowledge Studio® Speeds Stamping Process Selection, Increasing First-time-through Rates

Ford Motor Company needed to speed and standardize the selection of sheet‑metal stamping processes, a task that had relied heavily on individual engineers’ experience and time‑consuming trial‑and‑error. Ford Mexico had captured over 3,000 successful stamping runs across five years but lacked an automated way to apply that domain knowledge to reduce scrap, improve material utilization and raise First Time Through (FTT) rates, so they turned to Altair and its Knowledge Studio machine‑learning solution.

Altair worked with Ford to build and validate predictive models in Knowledge Studio, testing multiple algorithms and selecting a decision‑tree model that exceeded 90% accuracy (with combined datapoints approaching near‑perfect selection). The Altair solution automated process selection, tripled projected throughput, increased FTT rates, reduced rework time and preserved Ford’s in‑house know‑how for faster operator training.

Ford Motor Company