Case Study: Multi-Plant Manufacturing Company achieves 90% reduction in scrap and cuts escaped defects to 0.5% with Hertzler Systems Inc (GainSeeker Suite)

Creating a Data-Driven Culture Results in 90% Reduction in Scrap

Multi-Plant Manufacturing Company, a multi-plant manufacturer of metal products, was struggling with high scrap and rework, escaped defects, and a chaotic, reactionary problem-solving culture driven by a lack of trusted, real-time data. With staff spending 60–70 hours a week on manual data collection and reconciliation, the company engaged Hertzler Systems Inc and its GainSeeker Suite to provide centralized, actionable quality data and break the cycle of firefighting.

Hertzler Systems Inc implemented GainSeeker Suite along with training and coaching to automate data collection, create a single trusted data source, and support structured problem solving. The result was a dramatic performance improvement: 90% reduction in scrap and rework, data-capture effort cut from 60–70 hours to under 5 hours per week, and escaped defects reduced from 8% to 0.5%, while the organization shifted from reactionary to proactive decision-making.