Manufacturer Increases Production By 30% With GLSS
Home » Case Study » Manufacturer Increases Production By 30% With GLSS
United States
Manufacturing
Operations
30%
- The problem: A leading industrial equipment manufacturer faced a critical challenge: their high-volume roller conveyor production wasn’t keeping pace with growing customer demand.
- With GLSS Green Belt Training & Certification setting the stage for a remarkable transformation, the organization increased production by 30%.
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The manufacturing facility’s production floor was struggling with mounting inefficiencies that threatened its market position. Workers faced daily frustrations with lengthy setup times, inconsistent processes, and communication breakdowns. These challenges weren’t just numbers on a spreadsheet – they represented delayed shipments to customers, stressed team members, and missed revenue opportunities.
The company recognized that without a scientific approach to process improvement, it risked falling behind competitors and losing valuable market share. Additionally, rising operational costs and increasing customer expectations made it clear that maintaining the status quo was not an option.
The leadership team knew they needed a comprehensive solution that would not only address immediate concerns but also build a foundation for sustainable improvement. The company knew they needed a game-changing approach to streamline their operations.
After careful consideration, they partnered with GLSS for Green Belt Training & Certification, setting the stage for a remarkable transformation in their production facility. The decision to pursue GLSS certification would prove to be a turning point in their journey toward operational excellence.

Through rigorous analysis and GLSS-guided investigation, the team dove deep into their operations and uncovered four key issues holding them back:
- Production bottlenecks caused by poor coordination between machinery operators and supervisors, leading to unnecessary downtime and reduced throughput
- Language barriers created confusion during shift changes and critical operations, resulting in miscommunication and potential safety concerns
- Supply chain hiccups left workers waiting for essential materials, causing unexpected delays and production interruptions
- Inconsistent equipment setup procedures lead to quality variations and increased scrap rates

Armed with GLSS’s Green Belt Training and a newfound perspective on process improvement, the team implemented creative and effective solutions:
- Designed custom spacers for precise machine setup, eliminating guesswork and reducing variation in product quality
- Created visual work instructions that transcended language barriers, ensuring consistent understanding across all shifts
- Reorganized the production floor layout to optimize workflow and minimize unnecessary movement
- Established a new communication system that kept everyone in sync, including daily huddles and visual management boards
- Implemented standardized work procedures that made training new operators more efficient and effective

The impact of these changes exceeded expectations and delivered measurable improvement from 415 to 537 units per shift. Output continues to increase due to impact across multiple areas:
- Production cycle times dropped significantly, allowing for more output per shift and improved customer satisfaction
- Setup times between product changes were cut in half, increasing available production time
- Team communication improved dramatically, reducing errors and rework while boosting morale
- Worker satisfaction increased as processes became more streamlined and less frustrating
- Production capacity expanded without adding extra resources, improving the bottom line
- Quality metrics showed sustained improvement, leading to fewer customer complaints

with GLSS

This success story showcases the power of GLSS’s unique approach to process improvement and the value of its Green Belt Training program. Through their innovative training methods and practical tools, the team achieved results in weeks that might have taken months with traditional approaches.
The project did more than just boost numbers. It transformed how the team worked together and thought about continuous improvement. The GLSS methodology provided a structured approach that enabled quick wins while building a foundation for sustained success.
With their newly acquired GLSS Green Belt skills, the organization is now equipped to tackle future challenges and maintain its competitive edge in the fast-paced manufacturing industry. This victory marks just the beginning of their journey toward operational excellence, with the team now positioned to replicate these improvements across other areas of their operation.
*We value our clients’ confidentiality. While we’ve changed their names, the results are real.

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