Latest / The Manufacturing Podcast with Fexingo: Factories, Supply Chains, and Industrial Business
How a Michigan Factory Cut Scrap Rate to Near Zero
Episode 18 of The Manufacturing Podcast visits a mid-sized auto parts factory outside Detroit that spent two years whittling its scrap rate from 8 percent to under 0.2 percent without buying a single new machine. Lucas and Luna unpack the three-part system that made it happen: root-cause triggers on every reject, statistical process control on every production line, and a bonus structure tied to quality instead of volume. The hosts walk through how one operator's simple idea — a light that turns red when a drilling bit wears past tolerance — saved the plant $1.4 million in its first…
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