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Representative illustration: A vertically integrated building-products maker had vinyl siding scrap above 25%, eroding the division's profitability.

Case Study · Aerospace & Manufacturing

A vertically integrated building-products maker had vinyl siding scrap above 25%, eroding the division's profitability.

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1Challenge

Scrap exceeded 25%, and gauge distribution plus PVC and ASA additive usage were well above industry standards.

2Approach

  • Used one extrusion line, about 15% of siding output, as the prototype for all lines
  • Ran four joint CI teams using closed-loop problem solving and Lean Six Sigma tools such as Gage R&R and 5S
  • Set SPC limits by product family and trained operators through senior staff before full rollout

3Results

42%

Reduction in overall giveaway

13%

Less scrap from PVC coating variation

18%

Less scrap from ASA coating variation

The CEO brought USC back after earlier results at another building-products company.

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© USC Consulting Group 2026 | Aerospace & Manufacturing. Representative industry image. Results are engagement-specific; sizing and forecast figures are labeled as such.