Manufacturer Improves Order Fulfillment By 86% With GLSS
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Michigan
Manufacturing
Operations
86%
- The problem: A manufacturer faced increasing delays in order fulfillment, taking an average of 15.2 hours, with some taking as long as 200 hours. This excessive time frustrated customers and damaged the company’s reputation.
- Determined to fix these issues, the organization partnered with GLSS Green Belt Training & Certification. GLSS’s expertise in Lean Six Sigma provided the structured approach needed to reduce the time to 2.2 hours, an 86% improvement.

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In today’s competitive marketplace, efficient order fulfillment is the backbone of customer satisfaction. This organization faced a growing issue: their order fulfillment process wasn’t keeping pace with demand. Delays in completing orders led to late shipments, straining customer relationships and tarnishing their reputation. Compounding the issue, workers spent significant time on non-production tasks, which drove up labor costs and slowed operations.
The organization knew they couldn’t afford inefficiencies. To meet customer expectations and stay ahead, they had to find a way to streamline their process, reduce delays, and maximize productivity. To tackle these challenges, they turned to GLSS Training & Certification for expert guidance and an innovative approach to process improvement.
Upon examining their operations, it became clear that a key bottleneck was the time operators spent gathering product samples for quality testing. This task, while essential, pulled operators away from their primary responsibility—keeping the production line moving.
The reliance on operators for sample collection disrupted workflows, causing production slowdowns and compounding fulfillment delays. While everyone understood the importance of testing, the system needed an overhaul to balance quality control with production efficiency.

With GLSS’s guidance, the organization implemented practical, targeted changes to address these inefficiencies:
- Reassigning Responsibilities: Sample collection was shifted from production operators to Quality Technicians. This allowed operators to remain focused on their primary roles.
- Secondary System for Flexibility: In cases where Quality Technicians weren’t available, operators were allowed to deliver samples during scheduled breaks, ensuring minimal disruption to production.
- Empowering Team Leads: Team leads and maintenance staff was trained to handle sample delivery when necessary, distributing the workload more effectively.
These simple but strategic adjustments helped maintain production flow while ensuring that quality testing continued without delays.

The changes delivered immediate and impactful results:
- Fulfillment Time Reduced: Order fulfillment time dropped from 15.2 hours to just 2.2 hours—an impressive 86% improvement.
- Increased Efficiency: By keeping operators on the production line, the organization reduced labor costs while speeding up operations.
- Improved Customer Satisfaction: Faster order fulfillment enhanced the customer experience, strengthening loyalty and trust.

While the organization continues to refine the process for weekend shifts, the overall improvements have positioned them to handle customer orders more efficiently than ever before.

with GLSS
This project highlights the power of GLSS Training & Certification in driving meaningful process improvements. By combining innovative instructional design with practical solutions, GLSS helped the organization achieve faster results and lasting impact.
With streamlined workflows, reduced fulfillment times, and happier customers, the organization is now poised for sustained success. Thanks to GLSS, they’ve built a foundation for continuous improvement and are better equipped to meet the challenges of a dynamic business landscape.
*We value our clients’ confidentiality. While we’ve changed their names, the results are real.

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