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 profit drains in manufacturing, responsible for up to 42% of scrap losses and reducing margins by as much as 40%.

This playbook gives manufacturers a step-by-step roadmap to eliminate waste caused by process variability, standardize operations, and build lasting control systems.

✅ What You’ll Learn

• How to identify, measure, and eliminate scrap caused by process drift, machine variability, and inconsistent operator practices.
• Proven methods for standardization, monitoring, training, and maintenance that cut scrap at the source.
• A seven-step implementation framework blending Lean, Six Sigma, and TPM to stabilize processes and sustain improvements.

✅ Key Insights

• Scrap Types: Setup (5–12%), Run (65–75%), Changeover (22–28%).
• Root Causes: Poor documentation, inconsistent training, equipment maintenance gaps, and unmonitored variables.
• Impact: 15% material waste, 25% lost capacity, 30% productivity decline, and 20% wasted resources.

✅ Results You Can Expect

• 30–45% scrap reduction within 12 months.
• $275K savings per line annually with ROI of 3:1 to 8:1.
• Higher product quality, reliable delivery, and stronger customer trust.

By investing in people, processes, and technology, this playbook helps manufacturers transform scrap into savings, achieve operational excellence, and secure a lasting competitive edge.