At Pease Industries, a large Midwestern USA manufacturer of residential entry doors, operators, managers, and consultants formed a Sigma-Lean team and took waste off the line that created the resin and glass inserts for high-end residential entry doors. Among other things they ceased batch operation and redeployed operators who were no longer needed on the line. Results: 1) one-piece flow was established; 2) productivity was increased by 62%; 3) the defect rate was reduced to 11% from an origina...

BPIR Categories

5.5.3 Improve process/product performance
14.3.2 Implement an improvement approach/method/technique

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