Case Study: Senior Flexonics - GA Precision achieves 30% tooling capability gain and 20% uptime improvement with Hertzler Systems Inc (GainSeeker Real‑Time SPC)

GainSeeker ® Real-time SPC Eliminates Costly Guessing

Senior Flexonics - GA Precision, a Wisconsin manufacturer of turned and complex metal components for aerospace, medical, construction, agricultural and automotive markets, lacked a dependable way to determine tool life across thousands of tools. Business Unit Manager Phil Kapalczynski suspected tooling vendors weren’t meeting claimed tool life, but paper records were incomplete and cumbersome. Hertzler Systems Inc provided GainSeeker Real-Time SPC to capture accurate, automated tool-life data.

Hertzler Systems Inc implemented real-time data collection with GainSeeker, giving operators an easy data-entry process, real-time email alerts when tools fail or reach life thresholds, and automatic machine shutdowns at wear points to prevent scrap. The solution delivered measurable impact: tooling capability up 30%, machine uptime improved 20%, and scrap reduced by 10%, with notable improvements in tool testing and standard-setting within the first 10 days.

Senior Flexonics - GA Precision

Kapalczynski

Senior Flexonics