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Discover how Elementary's AI vision system transformed quality control.

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Welcome to Yield:
The New Blog from Elementary
Every pioneering product has a unique vision. Yield, Elementary's new blog, is committed to sharing the stories, ideas, and perspectives that illuminate our journey towards a zero-defect world.
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Analytics
The Hidden Cost of Delayed Quality Data: Why Weeks-Old Reports Are Costing Manufacturers Millions
Eddie Mancera
Head of Product
February 12, 2025
•
3 min read
Articles
Analytics

The Hidden Cost of Delayed Quality Data: Why Weeks-Old Reports Are Costing Manufacturers Millions

Eddie Mancera
Head of Product
February 12, 2025
•
3 min read
The Hidden Cost of Delayed Quality Data: Why Weeks-Old Reports Are Costing Manufacturers Millions

Manufacturing's dirty secret: most quality managers operate in the dark. While production lines run 24/7, quality data often arrives weeks after problems occur. By then, defective products have shipped, materials have been wasted, and the same issues have replicated across multiple shifts.

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This delayed reporting isn't just inefficient—it's increasingly indefensible in an era of real-time data. Yet the practice persists, largely because "that's how we've always done it."

Consider the case of a major paper manufacturer that recently challenged this status quo. Their quality managers previously spent hours collating weekly reports, discovering critical issues long after they occurred. The result? A staggering 22% defect rate that seemed impossible to reduce.

Their shift to daily automated reports revealed an uncomfortable truth: most defects stemmed from easily correctable process variations that, left unchecked, compound over time. Within 24 hours of implementing daily monitoring, their defect rate plummeted to 0.5%.

The implications extend beyond numbers. Quality managers transformed from reactive firefighters into proactive process optimizers. Instead of asking "what went wrong last month?" they now address "what's trending wrong today?"

This shift raises uncomfortable questions about industry-standard reporting practices. If weekly or monthly quality reviews are causing manufacturers to operate fundamentally blind, why do we accept them as normal?

The answers aren't simple, but the costs of inaction are clear. As one quality manager noted, "We spent years thinking our process was as good as it could get. Turns out we just couldn't see the problems in time to fix them."

For manufacturing leaders, the challenge now isn't technical—it's organizational. The tools for real-time quality monitoring exist. The question is whether we're ready to abandon comfortable but costly delays in favor of uncomfortable truths delivered daily.

Articles
Analytics
Eddie Mancera, Head of Product

A product leader who transforms early-stage startups through thoughtful product definition and design. Brings extensive expertise in enterprise software and AI, with a proven track record of turning nascent ideas into market-ready solutions.

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January 30, 2024
•
4 min read
Why Are Product Recalls So Costly and What Can You Do to Avoid Them?
Why Are Product Recalls So Costly and What Can You Do to Avoid Them?
Product recalls are expensive. When manufacturers discover that their products contain defects or are not compliant with safety standards, they are responsible for notifying the consumers and removing all affected items from the shelves, warehouses, storerooms, and customers’ homes.
Anh Cao
Director of Demand Generation
December 12, 2023
•
2 min read
Tool Tuesdays: Embedded Analytics
Tool Tuesdays: Embedded Analytics
In addition to real time defect detection, Elementary comes equipped with powerful analytics capabilities embedded within the user interface.
Ed Chan
Senior Product Manager
elementary
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