Manufacturer Improved On-Time Completion By 157% With GLSS
United States
Manufacturing
Operations
157%
- The problem: The deburr process was constantly missing its on-time delivery targets. The company was spending up to $10,128 per week in overtime, and this wasn’t just draining the budget—it was burning out the team.
- With GLSS, this manufacturer improved their on-time completion rate from 35% to 90%—a 157% improvement.
Speed and reliability go hand in hand in the manufacturing industry. If one part of the process falls behind, it can throw off the entire schedule, leading to missed deadlines, unhappy customers, and higher costs. One manufacturer was feeling the pressure in their deburr process, where parts weren’t being finished on time.
Looking for a real solution—not just a quick fix—the team turned to GLSS’s Lean Six Sigma Green Belt Training & Certification. Known for its simple, practical approach to improvement, GLSS helped the team take control of the situation. They also embraced Ethical Efficiency™, a principle that encourages solutions that benefit not just the company’s bottom line, but the well-being of its people too. The goal was clear: improve the process in a way that’s both effective and fair.
The deburr process was constantly missing its on-time delivery targets. When that happened, the rest of production had to scramble to catch up. The company was spending up to $10,128 per week in overtime, with six employees logging an extra 60 hours each week just to meet customer demand.
This wasn’t just draining the budget—it was burning out the team. With so much riding on one step in the process, it became obvious that improvement wasn’t optional—it was critical to keeping the business running smoothly and sustainably.
With the structured GLSS improvement process as their guide, the team uncovered two big problems:
- Tools and materials were poorly placed, which meant operators wasted valuable time walking back and forth instead of focusing on their work.
- The scheduler was juggling two separate deburr areas, both handling the same parts. This created unnecessary complexity and confusion.
These issues created daily chaos. Instead of having a steady, predictable workflow, the team was constantly playing catch-up—and it was taking a toll.
Thanks to what they learned in their GLSS Green Belt Training, the team rolled out a set of clear, straightforward improvements:
- All tools and supplies were moved to a central location, so everything needed was within reach.
- The two deburr areas were merged into one, reducing duplication and making scheduling simpler.
- Incoming shelves were placed closer to the operator stations, cutting down on wasted motion.
- Job planning was done in advance, giving everyone more visibility and structure each day.
These small changes added up to a big difference. The deburr process became easier to manage, and the team finally had the setup they needed to succeed.
The turnaround was dramatic. The team improved their on-time completion rate from 35% to 90%—a 157% improvement that helped the company deliver on promises and build stronger customer relationships.
Just as important, overtime was reduced by 28%, saving money and improving work-life balance for employees. With less chaos and more consistency, team members felt more supported, and the company was able to keep up with demand without burning people out.
with GLSS
By using GLSS Training & Certification, the team was able to quickly spot what was going wrong and take meaningful action. The course’s step-by-step instruction and real-world examples made it easy for the team to apply what they learned right away.
This project showed that process improvement doesn’t have to be complicated to be powerful. By combining smart solutions with Ethical Efficiency™, the team not only boosted performance—they did it in a way that supported both people and productivity.
With a faster process, fewer delays, and a more energized team, the company is now set up for future growth—and ready to take on whatever comes next.
*We value our clients’ confidentiality. While we’ve changed their names, the results are real.
