Scrap-Reduction-Due-to-Inconsistent-Process-Control - Level 1

Scrap Reduction Playbook: Inconsistent Process Control – Level 1

Inconsistent process control is one of the biggest hidden cost drivers in manufacturing—responsible for up to 42% of scrap losses and cutting profits by as much as 40%. This playbook is your structured guide to eliminating waste caused by process variability.

What You’ll Learn

• The Scrap Problem – Why 5–20% of output is wasted in most industries and how process drift, operator error, and poor maintenance multiply losses.
• Root Causes – Gaps in standardization (67%), operator training (52%), and maintenance (41%) drive costly deviations.
• Types of Scrap – Setup scrap (5–12%), run scrap (65–75%), and changeover scrap (22–28%).
• Business Impact – Up to 30% productivity loss, 25% reduced capacity, and 20% wasted resources.

The Proven Solution

A seven-step framework combining Lean, Six Sigma, and TPM principles across three phases:

1. Standardize Procedures – Visual SOPs, parameter sheets, and document control.
2. Process Monitoring & Automation – Real-time sensors, drift detection, and MES integration.
3. Operator Training & Accountability – Certification, ownership, and consistent skills development.
4. Robust Maintenance – Preventive care, calibration, capability audits, and rapid-response protocols.
5. Root Cause Analysis – Data-driven investigations and systematic countermeasures.
6. Material & Recipe Control – Specification discipline and automated recipe management.
7. Documentation & Change Management – Preserve best practices, prevent disruptions, and ensure knowledge continuity.

Results You Can Expect

• 30–45% scrap reduction in 12 months
• $275,000+ savings per production line
• 3:1 to 8:1 ROI
• Stronger customer trust through quality and delivery reliability

Why It Works

• People – Skilled, engaged operators trained on process control principles.
• Processes – Standardization that removes variability across shifts and lines.
• Technology – Smart monitoring systems that prevent issues before they cause scrap.

👉 This playbook empowers manufacturers to cut waste, protect margins, and build lasting competitive advantage through disciplined process control.