---
title: "Quality control at MidState Plastics"
description: "A worked example for a $35M injection molder: quality tracking in Excel, defect reports two days late, and the numbers a real-time dashboard would have to hit."
doc_version: "2026-05-20"
last_updated: "2025-01-15T14:00:00.000Z"
canonical_url: https://www.lightforgeworks.com/blog/midstate-plastics-case-study/
---

# Quality control at MidState Plastics

# Quality control at MidState Plastics

MidState Plastics is a composite company: a $35M injection molder making automotive components. The workflow and the failure points are real patterns; the company and the numbers are illustrative.

## The problem

Quality tracking runs on Excel spreadsheets. Defect reports arrive two days late. The defect rate sits at 3.2 percent, and automotive customers are complaining.

## The build

A quality dashboard on the production lines. It watches each line, flags defects as they happen, and charts the trends. It reads from the production systems already in place. Ten weeks to build. The client's team spent about ten hours on it.

## The numbers it would have to hit

- Defect rate: 3.2 percent down to 1.8, a 44 percent cut
- Defect reporting: two days to same-shift
- Savings at that defect rate: roughly $547,000 a year in rework and scrap

[Read the full walkthrough →](/blog/midstate-plastics-case-study-full)

## Interactive demo

<div class="solution-embed">
  <iframe src="/static/demos/midstate-plastics/midstate-plastics-demo.html" width="100%" height="600" frameborder="0" style="border-radius: 8px; box-shadow: 0 4px 12px rgba(0,0,0,0.1);"></iframe>
  <p style="text-align: center; margin-top: 10px; font-style: italic; color: #666;">Interactive demonstration of a real-time quality control dashboard approach</p>
</div>

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