Case study · Mining & Metals
Steel operation cuts scrap 30% for $45M in benefits
A steel operation needed lower scrap that would last. USC built a shared baseline, ran root-cause problem solving with the employees who run the process, and built the gains into daily reviews.
Results
$45M
in benefits
30%
reduction in scrap
The improvements were built with the people who run the process.
The situation
Scrap was too high, and improvements made on one shift were not carrying over to the next.
What the assessment found
- No shared view of where scrap losses occurred
- Fixes not sustained from shift to shift
- Actions not owned within the operating system
How the work was done
Diagnose: one shared baseline
Built a shared baseline from data review and process observation.
Improve: test with employees
Ran root-cause problem solving with employees testing changes on the line.
30%
reduction in scrap
Sustain: own it daily
Added visual measures, daily reviews and named owners in the management operating system.
Lasting impact
Scrap fell 30%, with improvements built by the people who run the process and owned in daily reviews.
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