What manufacturers who use Ellistat every day have to say
Adopting automated machine tool control software is an investment that involves both the shop floor teams and management. Before signing on, quality managers always ask the same question: Does it really work on an actual production line with real operators? The testimonials below provide concrete answers. They come from French manufacturers (automotive equipment suppliers, precision subcontractors) who have deployed Ellistat in their workshops and measured the results over time.
LISI Aerospace: Less Scrap, Greater Responsiveness in Adjustments
LISI Aerospace, which specializes in fasteners and structural components for the aerospace industry, operates in an environment where zero-defect tolerance is not just a slogan but a contractual requirement. Before Ellistat, statistical process control (SPC — Statistical Process Control) relied on paper records and Excel spreadsheets that were updated at the end of each shift. The time between when a deviation occurred and when it was detected could be as long as several hours.
After deploying Ellistat across several production cells, the average setup time—that is, the time elapsed between the detection of a nonconformity and the restoration of process compliance—was reduced by 40 %. Real-time control charts allow operators to take action before drift causes parts to fall outside tolerance, rather than after the fact.
«We’ve become more responsive to process alerts. Operators can spot a trend before a problem actually occurs. It’s this shift in approach—from reactive to preventive—that has had the greatest impact.»
— Quality Manager, LISI Aerospace
The scrap rate for the monitored items decreased by 28 % over the first twelve months, a result that is directly reflected in the monthly cost of non-quality (CNQ).
Kartesis: ROI Measured in Less Than Six Months
Kartesis, an automotive supplier specializing in steering systems, approached the Ellistat project with a clear requirement: the return on investment had to be quantifiable and achieved quickly. The company was already producing quality metrics, but consolidating them manually took quality technicians several hours of work each week.
The first ROI driver identified was the time savings on reporting. Before Ellistat, producing the weekly quality dashboards took an average of 4 to 5 hours per week per site. After automation via the platform, this time has dropped to less than 30 minutes, freeing up technicians to perform value-added analyses.
The second factor was the reduction in inspection costs. By improving the reliability of capability indices (Cp and Cpk—metrics that measure a process’s ability to remain within tolerances), Kartesis was able to reduce the frequency of inspections on certain stable product lines without compromising quality.
«We calculated the ROI over six months: between the time saved by technicians and the reduction in inspection costs, Ellistat paid for itself. After that, everything we save on scrap is pure profit.»
— Industrial Director, Kartesis
In total, Kartesis estimates the cumulative ROI over eighteen months at a factor of 3,5x compared to the initial investment in licenses and deployment.
What these feedback reports have in common
Based on a review of several customer testimonials, three factors consistently emerge as key to ensuring that the deployment yields measurable results.
Hands-on experience in the field. Software that operators don't use doesn't generate any profit. In documented cases, the simplicity of the Ellistat interface—designed for use on the shop floor, not just in the office—is cited as a key factor in its adoption.
Connecting to existing data. Integration with CMMs (Three-Dimensional Measuring Machines) and the measurement systems already in place prevented duplicate data entry and ensured the reliability of the data used to generate the control charts.
Start-up support. Several quality managers emphasize that the technical and methodological support provided during the first few weeks was crucial to embedding SPC best practices within the teams.
Create Your Own Experience
The metrics presented here—reduction in scrap, savings in setup time, and six-month ROI—are not theoretical projections. They were measured on industrial production lines in France, across demanding industries. Every production context is different, and the observed gains will vary depending on the initial level of quality maturity, the volume of SKUs managed, and the operating procedures in place.
The best way to find out what Ellistat can do for your organization is to test it on your own data, using your own processes. Request a personalized demo to get a concrete sense of its potential for your specific context.