Process studies and improvement efforts typically call for new instrum
entation on the process in order to collect the data they have deemed
necessary. This can be intrusive and expensive, and resistance to the
extra workload often foils the study before it begins. The result is n
either interesting new knowledge nor an improved process. In many orga
nizations, however, extensive historical process and product data alre
ady exist. Can these existing data be used to empirically explore what
process factors might be affecting the outcome of the process? If the
y can, organizations would have a cost-effective method for quantitati
vely, if not causally, understanding their process and its relationshi
p to the product. We present a case study that analyzes an in-place in
dustrial process and takes advantage of existing data sources. In doin
g this, we also illustrate and propose a methodology for such explorat
ory empirical studies. The case study makes use of several readily ava
ilable repositories of process data in the industrial organization. Ou
r results show that readily available data can be used to correlate bo
th simple aggregate metrics and complex process metrics with defects i
n the product. Through the case study, we give evidence supporting the
claim that exploratory empirical studies can provide significant resu
lts and benefits while being cost effective in their demands on the or
ganization.