Manufacturer Increased Epoxy Production Output By 45% With GLSS
Pennsylvania
Manufacturing
Operations
45%
- The problem: The manufacturer was consistently missing projected ship dates for epoxy-filled parts. Orders took longer than expected to complete, which led to higher labor costs and growing frustration on the shop floor.
- Using the structured approach from GLSS, the team was able to produce 20 more parts per hour on average, from 44 parts to 64 parts—a 45% improvement.
In high-volume manufacturing, time really is money. When a production line falls behind—even slightly—it can snowball into late shipments, frustrated teams, and rising costs. That’s exactly what this manufacturer was facing with their epoxy-filled parts. Production was lagging, deadlines were slipping, and labor costs were climbing. Looking for a better way forward, the organization turned to GLSS’s Lean Six Sigma Green Belt Training & Certification—a proven partner in making smart, sustainable improvements.
They chose GLSS not just for its step-by-step process and practical tools, but because the training aligns with Ethical Efficiency™—a values-driven approach that delivers real results while respecting people and purpose. With GLSS’s support, the team set out to improve their process, reduce frustration, and increase output—without cutting corners.
The team’s epoxy-filled parts were consistently missing their projected ship dates. Every delayed order meant longer working hours, higher labor costs, and growing tension on the shop floor. Team members were doing everything they could, but the process just wasn’t efficient enough to keep up with customer demand. It became clear that if the company wanted to meet deadlines and reduce waste, something had to change.
In the world of manufacturing, on-time delivery is more than a goal—it’s a must. Without reliable systems and tools, even the most dedicated teams can struggle. And that’s why process improvement isn’t just helpful—it’s critical to long-term success.
Once they applied what they learned in GLSS’s Green Belt Training, the team quickly found the root cause: the tooling simply wasn’t up to the task. Workers had to manually fill epoxy into parts using equipment that didn’t hold the tubes in place properly. The result? Overfilled tubes, excess material, and time-consuming rework.
Even with everyone working at full speed, quality and consistency were tough to maintain. The process wasn’t just slow—it was unpredictable and wasteful. The team needed a reliable way to streamline the epoxy process and boost productivity.
Thanks to the structured improvement methods from GLSS, the team focused on a practical solution: redesign the mold. They created a new tool that held the tube securely and allowed the epoxy to fill cleanly and evenly. No more overfilling, no more wasted material, and no more extra steps to fix mistakes.
The new mold was a game-changer. It didn’t just help workers do their jobs faster—it made the process smoother and more accurate. The fix was simple, effective, and entirely built by the team themselves. And that’s what GLSS Training is all about: giving people the tools to create lasting solutions.
The impact was immediate. With the new mold in place, the team increased their production from 44 parts to 64 parts per hour—a 45% improvement. That meant faster turnaround, lower labor costs per unit, and much more consistent output.
Not only was each part more uniform and easier to produce, but the team eliminated the waste of over-processing entirely. Productivity rose. Stress dropped. And morale skyrocketed.
With better tools and a smarter process, employees could focus on doing great work—instead of battling avoidable problems.
with GLSS
This wasn’t just a quick fix—it was a long-term upgrade powered by GLSS’s innovative and easy-to-follow training. The GLSS Training & Certification didn’t just help the team improve their epoxy process—it taught them how to think differently, work more efficiently, and tackle future challenges with confidence.
By focusing on Ethical Efficiency—doing what’s right for the business and the people who power it—this organization made changes that were fast, fair, and effective. They proved that with the right training and mindset, it’s possible to increase output, reduce costs, and empower employees all at once.
Now, with a stronger process in place and a more engaged team, the company is ready to take on future demand—delivering quality products on time, every time.
*We value our clients’ confidentiality. While we’ve changed their names, the results are real.
