Eliminating Hydraulic Hose Failures in Construction Industry
Bringing down annual warranty claims from £80,000 to £0 for an OEM in the construction industry.

Challenge
A client, operating in the commercial cranes and lifting industry, was facing substantial warranty claims amounting to approximately £80,000 per annum due to leaks in their existing hose and fittings products and crimp system.
Initial Assessment
Upon hearing the client's challenge, our immediate focus was on identifying the root cause of the issues. Detailed discussions with the client revealed that the problems stemmed from a lack of staff training on hose production and installation, combined with a complex hose system that was difficult for inexperienced engineers to manage.
Solution Offered
Our goal was to eliminate all hose and adapter failures for the client. To achieve this, we proposed a switch to a 1-piece, no-skive hose and fittings system, while also reducing their overall hose range to a few products that covered all their requirements. Additionally, we replaced their dial-type adjustable crimper with a fixed die crimper featuring a dead stop, removing another potential failure point in the hose manufacturing process.
To ensure accuracy, we introduced a T-marking process for the hoses to confirm correct insert depth and crimp diameters. We also implemented line marking on tightened fittings to easily identify any fittings that had not been tightened properly. To integrate these processes, we conducted comprehensive training courses for their engineers, covering the new hose products, manufacturing techniques, and installation processes, including the line marking system.
Implementation Phase
The implementation phase—from initial root cause analysis to product selection, stock implementation, and training—was completed in approximately one month and proceeded smoothly. We dedicated a technical engineer to the project full-time, ensuring a seamless product transition and project execution.
Results
Post-implementation, the client has experienced zero failures on their machines attributed to hydraulic hoses and adapters. We continue to provide ongoing training for any new staff to ensure they are fully equipped with the knowledge of the products and processes they will be using.
Key Performance Indicators (KPIs)
The most significant KPI is the reduction of warranty costs from an average of £80,000 per annum to £0 since the implementation of our solution.
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