Scrap & Quality Visibility

Surface defect patterns and quality losses before they erode margin and reach your customer.

The Scale of This Problem

Scrap cost for a mid-size precision stamping operation typically runs $800K–1.5M annually. The cost sits inside the ERP. Connecting it to the workcenter, the part number, the shift, and the machine that produced it requires EKAS.

Industry benchmark — precision metal stamping operations. Not derived from any specific customer.

The Problem

Quality Losses Hide in Plain Sight Until They Show Up in Margin

Scrap, rework, and quality escapes represent direct margin erosion — but most plants discover the full impact only after the losses have compounded across shifts, parts, and production runs.

Manual quality logs, disconnected inspection data, and delayed reporting mean defect patterns stay hidden until a customer complaint arrives or month-end scrap variance forces investigation.

Common Blind Spots

What Teams Usually Miss

Defect patterns are logged manually, if they're logged at all

Quality data is disconnected from production data — no clear link between part, machine, shift, and defect type

First Pass Yield trends are calculated in spreadsheets days after production

Failure modes are documented but never connected to live production events

Small recurring defects compound into margin loss before anyone notices the pattern

How EKAS Helps

From Quality Losses to Defect Intelligence

Track defect patterns by part, machine, and shift

See which defect types are recurring, where they're happening, and which parts are affected — automatically, not manually.

Monitor First Pass Yield in real time

Know your FPY by part number, workcenter, and shift — not days later in a spreadsheet.

Connect defects to documented failure modes

Link quality events to documented risk assessments and corrective actions in your failure analysis workflows.

Quantify quality loss impact

Track scrap units, rework hours, and quality hold time across machines, shifts, and production runs.

Business Outcomes

What You Get

Earlier detection of recurring defect patterns

Faster response to quality escapes before they reach customers

Clear visibility into scrap units and rework hours by part and machine

Connection between production events and documented failure modes

Governed First Pass Yield metrics for reporting and trend analysis

Reduced margin erosion from undetected quality losses

See Quality Visibility in Action

Bring a quality challenge. We'll show you how EKAS surfaces defect patterns and connects them to root cause.