Quality & Operational Performance at Scale
Building a Data-Driven Operating System
Reducing warranty claims by 75%
- Client
- A motorized equipment manufacturer
- Sector
- Industrials
- Headline result
- −75%
The challenge
Warranty failure rates approached 100% during the coverage period. Key dealers were leaving, market confidence was eroding, and there was no instrumentation to explain any of it — no defined KPIs, no warranty analysis process, and therefore no way to tell which failure was worth fixing first.
What we did
- Implemented a Manufacturing Quality Operating System (MQOS) built around time and data management with tracked, critical KPIs.
- Built a Warranty Binning System so effort went to the highest-impact failures rather than the most recently reported.
- Added a Product Development Quality Operating System to feed field failures back into design as preventive learning.
- Automated warranty analysis so the reporting was a by-product of the process rather than a separate exercise.
“The systems Envorso implemented delivered results AND confidence. With streamlined quality operations and rising dealer satisfaction, we’re better positioned than ever for sustainable growth.”
The practice behind this
Quality & Operational Performance at Scale
Connecting design, manufacturing and supply chain data into decisions — eliminating defects, modernizing the systems that hide them, and building engineering discipline that holds.
Read about this practiceWhere AI fits here
Includes the AI that genuinely pays here — pattern detection across warranty, test and field data — and the data quality it depends on, which is the layer most programs skip and then blame the model for.
Related
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Compliance that scales
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A global automotive manufacturerTwo hours to find out whether we recognise your problem.
No deck, no obligation. We listen, we tell you whether we have seen this before, and we say what we think it would take. If a Jump Start is the right next step we will say so — and if it is not, we will say that too.