How One Motor Manufacturer Cut Costs 20% With Smarter Testing
Discover how advanced magnetic testing equipment transformed quality control, slashed process costs, and turned a supplier into a strategic partner.
20%
Cost Reduction
Process cost savings achieved
1
Root Cause
Defect identified & fixed
100%
Vendor Control
Enhanced material quality
The Challenge
Inconsistent Quality
Raw material variations from vendors caused unpredictable subassembly failures in large induction motors.
Reliability Crisis
Product failures impacted customer trust and warranty costs spiraled as defects emerged in the field.
Rising Process Costs
Rewinds, scrap, and troubleshooting consumed resources without identifying the true root cause.
The Breakthrough Solution
During technical discussions about the Epstein Square Tester, the customer discovered it offered advanced hysteresis loop measurements-unlocking deeper diagnostic capabilities for both design and manufacturing teams.
01
Warranty Crisis
A year-old motor failed after rewinding despite prior satisfactory field performance
02
Custom Solution
Ferrites India modified equipment to enable rapid stack testing and diagnosis
03
Root Cause Found
Core defect identified as metallurgical problem related to welding process
04
Process Imprroved
Targeted manufacturing improvements prevented similar failures going forward
Measurable Impact
Defect Resolution
Direct stack analysis revealed true failure cause, enabling targeted manufacturing process enhancements
20% Cost Saving
Early magnetic inconsistency detection reduced failures, rewinds, wasted time and material costs
Vendor Excellence
Improved material qualification protocols reduced faulty inputs at source, streamlining quality assurance
Strategic Partnership
Customer recognized Ferrites India as solution partner, not just equipment supplier
Why this Matters
Technical Excellence
NABL-traceable testing per
IEC/ASTM/IS standards ensures
accuracy and compliance for critical
applications.
Customer-Centric Innovation
Customized equipment modifications
and practical support solve real-world
manufacturing challenges.
The Bottom Line: Combining advanced testing capabilities with
collaborative problem-solving, Ferrites India helped improve core quality,
reduce costs, and secure greater performance confidence for the largest
induction motors.