Case Studies

Real Plants. Real Results.

Detailed results from manufacturers who have implemented 10in6 — showing the specific challenges, modules deployed, and measurable outcomes achieved.

15% OEE improvement — AMPI (6 months)
3x OEE increase — Aluminum Extrusion (12 months)
$100k+ Saved on overpack — AMPI
Food & Beverage DQSMES

Paperless Quality Checks Eliminate Hundreds of Thousands in Overpack Losses

AMPI Associated Milk Producers Inc.
📈 Improved OEE by 15% in the first 6 months

The Challenge

AMPI needed to digitize quality checks, gain visibility into overpack issues, and improve OEE across their food processing lines — all while maintaining compliance with strict food safety requirements.

The Solution

AMPI implemented 10in6's Digital Quality System alongside the MES module. Quality checks moved from paper to touch-screen consoles, and for the first time, management had a real-time view of overpack data by line and operator.

Results

  • OEE improved 15% in the first 6 months
  • Hundreds of thousands of dollars saved by eliminating overpack
  • Labels now printed at the line in real time — label errors eliminated
  • Automated shift reports keep management informed without walking the floor

"After moving quality checks to 10in6, it was the first time we had a good view of overpack. This one change has resulted in hundreds of thousands of dollars in savings."

— Bill Swan, Division Manager

"Labels are now printed right at the line in real-time, including a date/time stamp. This has eliminated the risk of using incorrect labels."

— Joey Vogel, Production Manager
Automotive DQSMES

Audit-Ready Traceability and Paperless Quality Transform Customer Confidence

Tier One Automotive Supplier Automotive Components Manufacturing
📈 Paperless quality improves FTT and OEE

The Challenge

A Tier One automotive supplier struggled with customer audit anxiety, manual traceability processes, and quality data that was difficult to retrieve under time pressure from customers.

The Solution

10in6 deployed the Digital Quality System across quality check stations and assembly lines. Full traceability data now captured automatically at the point of production with complete product history accessible in seconds.

Results

  • Customer audit preparation reduced from days to minutes
  • Respond to customer traceability requests in minutes instead of hours
  • Quality, Engineering, and Maintenance now working from the same data
  • First-time-through (FTT) rates improved with earlier defect detection

"Before 10in6, customer audits were nerve-racking. Now we are proud to show our system and positive quality trends."

— Quality Supervisor

"The Track and Trace module has helped us significantly improve traceability. We can now respond to customer requests in minutes."

— Assembly Manager
Metal Manufacturing MES

OEE Triples in 12 Months — From 20% to 58%

Aluminum Extrusion Plant Aluminum Manufacturing
📈 OEE improved from 20% to 58% in 12 months

The Challenge

The plant had no reliable visibility into where efficiency was lost. Downtime was untracked, scrap was estimated, and management had no way to prioritize improvement efforts across multiple extrusion lines.

The Solution

10in6 connected directly to the extrusion equipment and deployed the MES module with full production reporting, Andon calls, and real-time dashboards. Within weeks, patterns became visible and improvement actions became focused.

Results

  • OEE improved from 20% to 58% in 12 months — a 3x increase
  • Downtime reasons now automatically captured and categorized
  • Constraint Manager identified top losses across all lines
  • New lines onboarded faster by tracking downtime reasons from day one

"We install 10in6 on each new line. It helps us get them up to speed quicker by tracking downtime reasons."

— Project Engineering Technologist, ArcelorMittal
Consumer Goods Manufacturing MESDQS

Unit Traceability, Error-Proofing, and OEE Gains Across Two Plants

AprilAire Indoor Air Quality Products & Services
📈 OEE improved 43% → 60% in first 3 months; downtime cut by 2/3

The Challenge

Both AprilAire plants tracked downtime and quality information primarily on paper — all OEE, downtime, and quality reports were produced manually. Data was incomplete and untrusted, making it difficult to prioritize improvement efforts or respond quickly to issues. The Poynette plant specifically needed serialized unit traceability to ensure every product shipped with the correct components.

The Solution

10in6 was first deployed at the Poynette, WI plant as part of a modernization initiative. Real-time production dashboards, Andon escalation, scan-to-pack traceability, and SPC monitoring replaced paper-based processes. Labels can only be printed once all components are scanned and final inspection is complete. Following the success at Poynette, AprilAire expanded 10in6 into their Madison, WI plant to address data access and workforce training challenges.

Results

  • OEE improved from 43% to 60% in the first 3 months at Poynette
  • Dehumidifier department OEE improved an additional 10% year-over-year
  • Downtime as a percent of total hours cut by 2/3 in the dehumidifier area
  • Payroll and Engineering each save 2–3 hours per week in admin time at Madison
  • Morning LMT meeting prep time reduced from 30 minutes to 2 minutes per day
  • Serialized unit traceability ensures correct accessories and torque specs on every unit before shipping

"When we started using 10in6, OEE improved without any specific fixes — just putting the numbers out in front of operators enabled them to know where they were versus the production target."

— Jason Lettau, Process Engineering Manager

"We use 10in6 to monitor critical quality characteristics and to ensure every unit has the required accessories. This is done down to confirming the right number of bolts are torqued to the right force before we allow the product to get the final box label."

— Dave Young, Director of Manufacturing

"It used to take 30 minutes a day to gather and analyse data for our morning LMT meeting. Now it takes 2 minutes each day to know which lines to focus on and investigate the issues."

— Kenny Haferkorn, Process Engineer

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