Reduction of Scrap in Production
How Lean Six Sigma transformed a Swiss plastics factory's operations, delivering €95K annual savings. Apply these gains to your career in manufacturing or logistics.
Context & Problem
An injection molding factory recorded 8% scrap on a critical line. This generated annual overruns of €120,000.
Objectives
Reduce the scrap rate to less than 4% in 9 months.
DMAIC in Action
Measure
Precise tracking by defect type.
Analyze
70% of scrap due to molding temperature variations.
Improve
Installation of sensors + automatic press adjustments.
Control
Real-time SPC monitoring.
Result
Scrap rate dropped from 8% to 3.5%.
Estimated annual savings: €95,000.
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