When manufacturers say, “We need to cut costs,” one of the first places we suggest they look isn’t overhead or headcount; it’s the scrap barrel.
Every scrapped part doesn’t just cost material. It eats up machine time, operator attention, and scheduling bandwidth. In high-volume environments, that adds up fast. But the real challenge isn’t just reducing scrap, it’s preventing it in the first place.
- Start with process stability. A good part starts with a good process. If your team is relying on inspection to catch errors instead of building quality into the setup, you’re reacting too late.
- Standardize setup procedures. Clear, repeatable instructions help operators consistently hit “first part = good part.”
- Don’t overlook tooling. You can’t hit a ±.0005″ tolerance with a worn insert. Know your tool wear limits—and train your team to recognize when to measure, offset, or switch edges.
- Make First Article Inspection (FAI) meaningful. Don’t let the job “run” until your FAI confirms critical features are in spec.
- Prioritize training. Every operator should know exactly what “good” looks like—and how to achieve it on the first try.
Improvement doesn’t always mean working faster. Sometimes, you have to slow down to speed up—by dialing in processes, tooling, and training to reduce waste and boost throughput.
If this hits close to home, it might be worth a fresh set of eyes. Whether you’re stuck in firefighting mode or just need ideas to level up, sometimes an outside perspective can uncover what you’re too close to see.
What’s one area in your process where a small improvement could unlock a big gain?
