Scrap-Reduction-Playbook-Eliminating-Waste-from-Overproduction-and-Excessive-WIP - Level 2

Scrap Reduction Playbook: Eliminating Waste from Overproduction & Excessive WIP – Level 2

Manufacturers lose millions each year to scrap caused by overproduction and excessive work-in-process (WIP). This advanced playbook gives you the tools to identify root causes, quantify financial impact, and implement proven lean strategies that cut waste at its source.

You’ll learn how to:

✅ Measure and track scrap with industry KPIs (scrap rate, inventory turns, first-pass yield, WIP aging)

✅ Prevent overproduction through pull systems, kanban, and demand-driven planning

✅ Right-size WIP with line balancing, FIFO lanes, and visual controls

✅ Standardize processes and implement real-time quality monitoring

✅ Build cross-functional ownership to achieve sustainable results

By following this structured roadmap, you’ll unlock 30–50% scrap reduction within 12 months, boost quality and delivery, and free up working capital tied in wasteful inventory. This isn’t just about cost savings—it’s about creating a competitive, resilient, and future-ready manufacturing operation.