When process failures threatened both compliance and profitability, this manufacturer discovered how strategic operational analysis could deliver $98,000 in annual savings with just $50 in equipment - proving that the most expensive solution isn't always the most effective one.
A recurring wet-mess issue was creating cleanup labor, product waste, and safety concerns. The team assumed the fix would require new equipment and significant spend.
Only a short maintenance window was available and the facility did not want to add new equipment or complex controls.
This was a long-running issue no one could solve. The breakthrough came from a maintenance technician who remembered a simple control tactic his Army construction platoon used to prevent walk-aways. We adapted that idea to this process, tested it on the line, and the overfills stopped immediately.
It sounds unbelievable until you do the math: a $50 fix that removed a recurring loss worth roughly $98,000 per year.
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