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| A high quality flooring manufacturer scrapped more than 10% of product due to various defects, the biggest of which contributed to more than 5% of total waste, costing more than £660K per annum in production costs. |
| The largest of the scrap issues had existed as far back as any of the employees could remember and little understanding of the root cause was held. Through a rigorous problem solving approach, an understanding of all the causes of the scrap issue were established, allowing the problem to be dramatically and substantially reduced within a matter of weeks. |
By establishing a tracker to allow scrap trends to be followed daily, the value of the losses became highly visible and allowed the main issues to be focused upon. |
The remaining project duration was spent continuing to reduce the largest scrap issues, as well as ensuring the employees took on the knowledge and improvement structure, to sustain and continue to reduce the main scrap issue. |
| The project established a consistent reduction of approximately 30% of the main scrap issue, across 4 production lines, saving more than £200K per annum. |
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