Business Case
Capital-intensive compression molding business needs cash and lower costs for growth.
Expensive quality problem eroding market share.

Actions
Led TPS implementation in the business unit's 4 plants in U.S. & Mexico

Results

Before 12.8% 268 0.020 2089

Metric Scrap Internal PPM Customer Complaint Rate Output per employee

After 9.0% (-29%) 170 (-37%) 0.011 (-45%) 2723 (+30%)

Summary
Claims expense dropped 71%
Grew business 10% with the same headcount & capital equipment
Won 2002 President's Award - best of 26 business units worldwide