Case Study: Rolls-Royce achieves £500,000/year savings and 90% reduction in yield issues with IntraStage BlackBelt Manufacturing

Rolls Royce - Customer Case Study

Rolls Royce, a provider of safety-critical controls and asset intelligence for industrial power, marine, civil and military aerospace, faced highly complex products with tight safety and reliability metrics and needed to rapidly aggregate and analyze production data (AOI, AXI, ICT, FCT, ESS, failures, rework and ATP) and apply SPC across many variables such as CpK. To meet this challenge, Rolls Royce engaged IntraStage and implemented IntraStage BlackBelt Manufacturing for automated data management and advanced analytics.

IntraStage delivered a robust data model with OLAP cube analytics, out‑of‑the‑box quality reports and an open platform for custom reporting and enterprise integration. The solution enabled predictive SPC, cut defect analysis from two weeks to seconds, achieved a 90% reduction in yield issues, dramatically improved throughput yield and cycle time, and delivered sustained savings of £500,000 per year (reducing Cost of Goods Sold) since 2005.

Rolls Royce