New Program Cuts Manufacturing Scrap Loss

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Profits and studies show that today's corporate programs fail to eliminate costly manufacturing scrap. Joe Dunn learned this the hard way when he entered the manufacturing world 16 years ago. Creator of, he has helped manufacturers in several countries and US states increase net profits, productivity and lead time response through quality-cost reduction.

For two decades, Six Sigma has been the method of choice for improving quality and raising profits for manufacturers everywhere. “But the status quo is failing in today's economy,” says Joe Dunn, the foremost authority on the death of outmoded quality improvement methods.

Dunn's Scrapkillers has launched a new program that can reduce scrap losses in far fewer test trials than traditional methods, making the savings process cheaper and faster than before.

“Fifteen years ago the body of knowledge to improve quality was still fresh and inspiring, and many companies got real bottom line results. Nowadays too many plants are using the same tired methods or have given up altogether. New ways to reduce quality-related scrap, rework and waste are in,” he said.

Since Dunn began using cutting edge quality improvement methods ten years ago, manufacturers benefiting from them have enjoyed double and triple process capabilities. Dunn says a typical project goal for a medium-sized first tier manufacturer should be at least hundreds of thousands of dollars in annual scrap and rework, or a percentage of the plant's EVA or ROI.

As Dunn points out, however, the need to reinvigorate efficiency programs is hard for many to face.

“In most companies, Six Sigma and Lean Manufacturing departments are the sole methods of generating process improvements. Managers and trainers simply haven't accepted the reality that many standard Sigma methods don't work in today's high-efficiency shop,” says Dunn.

He also warns that many employers ignore the need to re-align their quality improvement approach at their plant's peril.

“Having a Sigma program is a way for companies to feel that everything's fine. They have the experts on call off site at a corporate office, who may come to train every couple of years. Those experts aren't out there on the shop floor using the fastest, clearest methods to help the lead operator solve his toughest technical problems. But the status quo is an easy way for companies to keep short-term costs low,” he said.

“Unfortunately the typical Sigma practitioners are still teaching complicated, expensive, darkly closed, non-graphical methods that often yield confounded – and useless – results,” Dunn said.

Nearly 60% of all Six Sigma initiatives fail to yield the desired results, according to experts who have been in the Sigma movement since its origin in the 1980s. Murray, Martin (2012-04-2012). “Is Six Sigma Still Effective?” Retrived 2013-10-19

A Fortune article stated that “of 58 large companies that have announced Six Sigma programs, 91 percent have trailed the S&P 500 since”. Morris, Betsy (2006-07-11). "Tearing up the Jack Welch playbook". Fortune. Retrieved 2013-10-19.

For more information, or to get Joe Dunn's free eBook “How to Eliminate Defects and Double Your Plant's Profit”, please visit

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