Case Study 10: Getting to Root Cause

Processes add value when they are running on customers orders. A process cutting dental ingots was considered low skill, menial and not one the operators wanted to run.

The machines were gravity fed, but the operators would wander off to other work areas and the process would stop when no material was loaded. Working with the team, it was determined that much could be done to improve the role, make it much safer and significantly increase productivity.

This company installed the machine as part of major capitol purchase two years ago.


A cell approach was implemented, bringing the machines together to reduce travelling, material handling was simplified, machines were cleaned, painted and sealed to prevent coolant leaks and the tools required for each machine were located on hand on shadow boards. It became an area people wanted to work in.

Output was improved from under ½ a ton to an average of a 1½tons per week equating to an additional £200K profit per annum - just by being there.

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Customer Profile


Main focus of activity
Process analysis and applying the 5S

An additional £200K profit per annum for the company




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