Automotive parts die caster cuts scrap by 52% with Monitizer | PRESCRIBE AI
Cutting scrap to unlock scalable growth
For one global automotive parts manufacturer, producing more than 300,000 die cast components and assemblies each year, reducing scrap was critical to supporting continued growth.
The goal was clear:
- Lower scrap rates
- Stabilize quality
- Optimize die casting performance
All without disrupting existing systems or production flow.
The results at a glance
By introducing Monitizer | PRESCRIBE, the manufacturer achieved:
- 52% scrap reduction in a single production batch
- More stable, repeatable quality
- A clear path to scale optimization across additional dies and cells
AI-driven process optimization with PRESCRIBE
To achieve this, the manufacturer worked with Monitizer, introducing PRESCRIBE on one of their 11 die casting cells. PRESCRIBE is an AI-driven solution that analyzes historic and live die casting data to learn which process settings deliver the best quality outcomes. Based on real-time production conditions, it proactively prescribes control adjustments, helping operators keep the process stable and reduce variation before defects occur.
Rather than just monitoring performance, PRESCRIBE gives manufacturers actionable control - turning data into decisions that directly improve quality.
Built to work with existing systems
The die casting cell used in the project was equipped with ItalPresseGauss high-pressure die casting machines, providing a stable production environment for deploying AI-driven process optimization.
The customer already had a Manufacturing Execution System (MES) in place to collect basic machine data. Because Monitizer is designed to integrate with existing equipment and software, implementation was straightforward.
“The customer already had their own MES for collecting basic machine data. As Monitizer is compatible with existing equipment and software solutions, this meant implementation was straightforward. We could add to their capabilities without them having to replace or update anything.” - Steven Li, Aluminum Project Director, ItalPresseGauss, China
Measurable impact, and clear potential to scale
In just one production batch, PRESCRIBE reduced the average scrap rate by 52% and is now helping the customer maintain this improved level of performance.
If similar results were replicated across all dies and products, the manufacturer could expect to save almost €130,000 per year in scrap reduction alone, before factoring in additional energy savings, productivity gains, and reduced rework. With strong results already proven, the next step is expanding PRESCRIBE to additional dies, unlocking even more value from existing production data.
Take control with Monitizer | PRESCRIBE Reduce scrap, stabilize quality, and unlock the full potential of your die casting processes with AI-driven process control.