Manufacturing · 2024
The Yield Line Nobody Budgeted For
Per-job yield against theoretical surfaced a scrap class nobody had priced — cutting it paid for the programme inside the quarter.
The problem
What was actually broken
Yield was a monthly average that hid which jobs leaked; operators knew the crease-heavy coils were problematic but nobody could prove it before the line ran them.
What we built
The system we shipped
We instrumented yield per slit programme with scrap-by-reason photographs, rated by operator and machine, so kaizen points at causes — not hunches.
What came out of it
- Yield vs theoretical per job and per coil family
- Scrap reason codes with linked photographic evidence
- Machine and operator yield tables for weekly reviews
Reported outcomes
- Material yield improvement
- +6.4%
- Material yield improvement
- Weekly schedule rework
- -31%
- Weekly schedule rework
- Average WIP age
- -18%
- Average WIP age
Representative outcomes from comparable engagements, rounded for illustration — not measured results from any single client. Client-confirmed numbers are shared under NDA during discovery.
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Enterprise System · 2024
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