Customer case study · STANLEY Healthcare
STANLEY Healthcare: investigating first-pass yield from unit to component
Connected production evidence helped the team investigate failures, monitor contract-manufacturer quality and feed findings back into engineering and design.
The manufacturing challenge
The published case describes healthcare products with complex electronic assemblies: many components and functions had to work together. The team wanted to improve product quality and first-pass yield, monitor PCBA modules supplied by contract manufacturers, and strengthen new product introduction before outsourcing production.
A pass/fail total alone could not explain the issue. Engineers needed to work back through the unit, its components and the underlying test evidence, then decide whether the next action belonged in production, test engineering or product design.
How the team used QualityLine
The workflow combined unit-level investigation, automated alerts and cross-correlation. Alerts brought relevant production changes to the attention of manufacturing, quality, engineering and R&D teams. The team used the analysis to investigate possible causes and compare the effect of parameter-limit changes.
The account also describes a feedback loop between production, engineering and design. Early failure findings supported design-for-manufacturability review and helped the team decide when unexpected test results required a return to R&D. Web-based access allowed the team to monitor contract-manufacturer performance remotely.
The reported results
Page 3 reports first-pass yield increasing from 63% to 94%: a change of 31 percentage points. A separate account on page 4 describes the project reaching 90% FPY by the end of its first week. The PDF does not state when the later 94% result was measured.
The same results page separately reports a failure-rate change from 37% to 2.3%. It does not define that measure or reconcile it with the FPY figures, so it should not be treated as the complement of the reported 94% FPY.
What this case demonstrates
The practical connection is between detecting a change, investigating the affected records and routing the finding to the team that can act. For a comparable evaluation, define first-pass rules, product scope and the measurement period before comparing results.
Explore the first-pass yield improvement workflow, root cause analysis and quality alerts.
Discuss your manufacturing challenge
Bring one production issue, the records you collect and the measure you want to improve. We’ll review the relevant workflow and evaluation scope.
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