Improving Quality & Reducing Scrap with Toolmind
KALLER & SERTEC Aluminium Structures
In collaboration with KALLER UK, SERTEC Aluminium Structures implemented Toolmind to improve production quality, reduce scrap, and increase operational reliability.
About SERTEC
SERTEC Aluminium Structures, part of the SERTEC Group based in the UK, is a leading manufacturer of aluminium body structures for the automotive industry.
With over 60 years of experience and advanced press capabilities, maintaining consistent quality and process reliability is critical to their success.
The Challenge
SERTEC identified a critical issue within one of their progression tools:
- Gas spring pressure was essential for dimensional accuracy
- Small deviations could lead to quality defects and scrap
- Failures risked impacting downstream processes and production efficiency
- Manual monitoring made it difficult to respond quickly enough
The challenge was clear:
How can you ensure consistent pressure control and prevent costly production errors?
The Solution: Toolmind
KALLER UK introduced Toolmind, a wireless pressure monitoring system, as part of a continuous improvement initiative.
Implementation included:
- Retrofitting sensors into the existing system
- Connecting to a centralized Toolmind Base Station
- Configuring pressure limits and monitoring thresholds
- Activating automated shutdown via relay when limits were exceeded
This enabled real-time monitoring and immediate response — without relying on manual intervention.
Automation in Action
With Toolmind in place, SERTEC was able to:
- Automatically stop production when pressure dropped below acceptable levels
- Prevent defective parts from being produced
- Reduce operator dependency for constant monitoring
- Improve overall process reliability
Instead of reacting to issues, the system now proactively protects production quality.
The Results
Shortly after implementation, SERTEC experienced measurable improvements:
- Significant reduction in scrap and waste
- Reduced troubleshooting time
- Improved confidence in production quality
- Estimated cost savings of thousands of pounds from avoided scrap and inefficiencies
Following this success, SERTEC expanded the solution to additional production lines.
Why Toolmind
Toolmind helps manufacturers move from reactive processes to controlled, data-driven production:
- Monitor pressure in real time
- Automate responses to prevent issues
- Reduce scrap and downtime
- Maintain consistent quality output
- Gain actionable insights into tool performance
Learn more about Toolmind:
- Toolmind Overview: [link]
- Toolmind Sensors: [link]
- Toolmind Base Station: [link]
Take Control of Your Production
Ready to reduce scrap, increase uptime, and improve quality in your operation?
Contact us today to see how Toolmind can benefit your production.