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Case Study – LTC Group & PrecisOR®

From Minutes to Seconds – How LTC Eliminated Production Stops Worldwide

AT A GLANCE

  • At LTC, measurement became a bottleneck because every inspection stopped production.

  • Manual and semi-automatic measurement processes led to recurring production interruptions.

  • The goal was to drastically reduce measurement times and avoid downtime.

  • With the PrecisOR®, measurement times were cut from several minutes to just a few seconds – without halting production.

  • The verifiable efficiency gains led LTC to roll out the solution globally.

Author: Dr.-Ing. Timon Burghardt, Head of Development, HECHT AG
Status: 20.04.2026

Reading Time: 5-10 minutes

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Our content is based on real industrial projects, profound metrology expertise, and decades of experience. It is developed by our experts and technically reviewed before publication.

TABLE OF CONTENTS

GLOSSARY

Transformer Laminations
Thin metal sheets used in transformer cores that require high geometric precision.

Quality Control
The inspection of components to ensure they meet specified requirements.

Optical Measuring System
A non-contact system for capturing geometries using cameras and sensors.

Automated Measurement
Measuring processes performed with minimal manual effort and high repeatability.

Process Interruption
Any step that causes production to stop or slow down.

When Measuring becomes a Bottleneck

The Legnano Teknoelectric Company (LTC Group), with 1,200 employees, is one of the world’s leading manufacturers of transformer laminations and cores. With production sites in Italy, Dubai, Taiwan, and Canada, LTC operates in a highly demanding environment: high volumes, stringent quality requirements, and globally synchronized production processes.

In this context, one factor became increasingly critical: the speed of measurement. In transformer core manufacturing, every lamination must be precisely inspected. For LTC, this created a fundamental conflict of objectives: ensuring quality versus maintaining production flow.

The Challenge:
Shorter Stops, Higher Throughput –
Redefining Measurement Cycles

Before introducing the PrecisOR®, inspections at LTC were carried out manually or semi-automatically. This resulted in:

This resulted in:

Production Stop

Every measurement required a complete halt of the production line.

Time Loss

Valuable minutes were lost repeatedly during each inspection cycle.

Process Clogs

Measurement times consistently led to recurring delays

Output Loss

Interruptions quickly snowballed across production.

Objectives: Resolving the Conflict Between Quality and Speed

LTC didn’t just want to improve measurement – they wanted to fundamentally rethink it. The requirements were clear:

  • Drastically reduce measurement times.
  • Virtually eliminate production downtime.
  • Integrate quality control as directly as possible into the process.
  • Create uniform, traceable standards across all locations.

In short: Measurement should no longer stop production – it should be completed in seconds.

The Solution: The HECHT PrecisOR®

With the PrecisOR®, HECHT developed a fully automatic optical measuring system specifically for transformer laminations. The decisive factor is not just the technology, but the change it enables: measurement remains a separate step, but one that no longer disrupts the rhythm of production.

The PrecisOR® enables:

Fully Automated Inspection

X-Y coordinate measuring table with servo drive.

High Precision

Accurate capture of length, width, angles, holes, radii, and notches.

Efficient Job Creation

Target-performance comparisons for rapid evaluation.

Optical Metrology

High-resolution cameras capture every detail of the component.

Automatic Documentation

Data is automatically saved to SQL databases.

The Result: From Minutes to Seconds

Category Previous Process With HECHT PrecisOR®
Integration & Environment Measurement often requires lab-like conditions Integrated into production process;
Robust operation in shop-floor environments
Time & Efficiency Several minutes per sheet
(requires production line stop)
Operator is occupied during measurement 		Measurement takes only seconds per sheet
(minimal line stop required):
  • Operator starts the process and is immediately free
  • Significantly shortened production cycles
Measuring Method Manual / Semi-automatic;
contact-based		 Fully automatic & optical:
  • Non-contact measurement of all geometries
  • Including notches & boreholes
Accuracy Operator-dependent;
High risk of error		 Operator-independent precision of ±0.05 mm;
Consistent quality
In use at LTC: A predecessor system of today's HECHT PrecisOR® – proven technology evolved into the current solution.

What was once a bottleneck is now fully integrated: LTC has long moved past the pilot phase and is rolling out the PrecisOR® as a global standard. With seven systems already in use and six more being delivered – from Italy to Dubai to Canada – the solution is firmly embedded in LTC’s global production.

“Previously, the production line had to be stopped for every measurement – which cost us valuable minutes every time. Today, the PrecisOR® measures in seconds, and production simply keeps running. We save an enormous amount of time in every shift; it’s a real game-changer for our efficiency.”

What This Means for Manufacturers

For manufacturers of transformer cores and metal components, the challenge remains the same: essential quality assurance must not become a bottleneck for production.

The LTC example proves that measurement is no longer a “necessary evil” or an obstacle; instead, as a fully integrated process, it supports the entire workflow. Especially in series production across multiple locations, this transition leads to a measurable increase in output, efficiency, and process stability.

With the PrecisOR®, LTC achieves maximum precision—directly at full production speed.

FAQ at a Glance

Maximum Efficiency: Measure laminations in the shortest possible time with 100% repeatability!

How can I make my production process more efficient?

By identifying process steps that interrupt production. As this case study shows, measurement in particular has a major impact on overall efficiency.

Why is measurement often a bottleneck in production?

Because it is frequently performed manually or requires the production line to stop. These interruptions add up and significantly reduce total output.

How to improve measurement without slowing production?

By drastically reducing the measurement time, allowing inspections to be carried out without substantially affecting the production flow.

How do shorter measurement times affect productivity?

Shorter measurement times mean fewer interruptions to the cycle. This increases output per shift and ensures more stable, predictable processes.

When is a multi-site rollout worthwhile?

Once the benefits have been clearly proven in ongoing operations. As seen with LTC, a measurable gain in efficiency often leads to the solution being deployed across all locations.

How does reducing downtime affect employees?

Fewer unplanned stops mean a less stressful workflow and higher planning reliability for the team on the line.

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    HECHT AG
    Ottmarsheimer Höhe
    Heinrich-Hertz-Str. 3-5
    74354 Besigheim
    Germany
    Tel. +49 (0)7143-8159-0
    Fax +49 (0)7143-8159-25
    info@hecht.ag

    www.hecht.ag

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    Informations

    Informations

    HECHT AG
    Ottmarsheimer Höhe
    Heinrich-Hertz-Str. 3-5
    74354 Besigheim
    Germany
    Tel. +49 (0)7143-8159-0
    Fax +49 (0)7143-8159-25
    info@hecht.ag

    www.hecht.ag

    de_DE