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Case studies · SQDCM results

Plants like yours, better every shift.

9 plants in 8 countries, one connected loop. Each story shows where the plant started, which modules it used, how fast it went live, and the numbers that moved: safety, quality, delivery, cost and morale.

Electronics-Assembly PlantPenang, Malaysia · 520 peopleMYFirst-pass yield 94.1% → 98.6% · unplanned downtime down 38%Before Six SMT lines, 94% first-pass yield, tier meetings run from a printed slideSafety5× near-misses reportedQualityFPY 94.1% → 98.6%Cost$410k / yr verifiedDaily ManagementMaintenanceQualityRoot CauseFactory IntelligenceRead the story →Live in 2 weeks · 9 months of resultsAuto-Components PlantPune, India · 220 peopleIN₹42 lakh/yr verified savings · rejections down 44%Before Paper 5S, ~40 defects a month logged, rejections above the OEM's targetSafety2 → 0 lost-time injuriesQuality−44% rejectionsCost₹42L / yr verifiedAuditsDefectsRoot CauseImprovementsInstrumentsOPLs and SOPsRead the story →Live in 9 days · 12 months of resultsPrecision-Machining PlantStuttgart, Germany · 340 peopleDECustomer PPM down 51% · audit prep from 2 days to 2 hoursBefore Findings in email, 2 days of prep before every customer auditSafety4× near-misses loggedQuality−51% customer PPMCost€180k / yr verifiedAuditsQualityInstrumentsRoot CauseReportsRead the story →Live in 3 weeks · 9 months of resultsIndustrial-Equipment PlantColumbus, Ohio · 410 peopleUS$320k/yr verified savings · 92% audit participationBefore An annual 5S event, forklift near-misses tracked on a whiteboardSafety−38% recordablesQuality−29% scrapCost$320k / yr verifiedAuditsSafetyRoot CauseImprovementsLeaderboardRead the story →Live in 2 weeks · 12 months of resultsFood-Processing PlantHo Chi Minh City, Vietnam · 480 peopleVNCustomer complaints down 40% · retailer audit passed cleanBefore Hygiene rounds on paper, three retailer complaints a monthSafetyCCP misses → 0 unclosedQuality−40% customer complaintsCost$95k / yr verifiedChecklistsDefectsMaintenanceQualityOPLs and SOPsRead the story →Live in 2 weeks · 10 months of resultsPharma-Packaging PlantKraków, Poland · 290 peoplePLRight-first-time 96% → 99% · audit prep 3 days → 4 hoursBefore Paper line clearance, 3 days to prepare for every GMP auditSafety3× near-misses reportedQualityRFT 96% → 99%Cost€120k / yr verifiedChecklistsQualityInstrumentsTrainingReportsRead the story →Live in 4 weeks · 8 months of resultsInjection-Molding PlantMonterrey, Mexico · 350 peopleMXScrap down 31% · $210k/yr verified savingsBefore 42 presses, 9% scrap, maintenance run from a WhatsApp groupSafety−33% recordablesQuality−31% scrapCost$210k / yr verifiedDaily ManagementMaintenanceRoot CauseImprovementsLeaderboardRead the story →Live in 10 days · 12 months of resultsSoy-Foods PlantHayward, California · 140 peopleUSZero Listeria positives in 12 months · $260k/yr verifiedBefore Pre-op sanitation on clipboards, a recurring Listeria positiveSafety−48% slip / first-aidQuality0 Listeria positives / 12 moCost$260k / yr verifiedChecklistsSafetyQualityMaintenanceOPLs and SOPsRead the story →Live in 1 week · 12 months of resultsBeverage-Bottling PlantCampinas, Brazil · 380 peopleBRLine OEE 61% → 74% · R$1.9M/yr verified savingsBefore Four lines at 61% OEE, breakdowns reported over the radio, 3 lost-time injuries a yearSafety3 → 0 lost-time injuriesQuality−52% underfill rejectsCostR$1.9M / yr verifiedMaintenanceDaily ManagementSafetyImprovementsLeaderboardRead the story →Live in 12 days · 12 months of results

Illustrative stories: composites of typical LeanOS rollouts, with plant and people details changed.