What was tried, what was difficult, what changed—and what another manager should know before starting.
A cross-functional team combined Pareto analysis, 5 Why and daily process confirmation to stabilize a progressive die line.
Measured result
62% less scrap
The planning team exposed capacity constraints, redesigned the tier meeting cadence and introduced a finite scheduling routine.
Measured result
OTD from 71% to 94%
Operators documented internal and external setup work, tested improvements weekly and standardized the best-performing sequence.
Measured result
Changeover time −41%