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How One Factory Cut Defects 90 Percent With a Single Board Change
Toyota's Georgetown, Kentucky plant had a persistent defect on door panel seals — 1.7 percent failure rate, costing $2.3 million annually in rework and warranty claims. Engineers traced the root cause to a two-centimeter gap in the assembly line's fixturing jig. Episode 61 of The Operator's Manual breaks down how a single physical modification — adjusting a metal guide by the width of a nickel — eliminated 90 percent of the defects within two months. No software, no AI, no new hires. Lucas and Luna walk through the decision tree: why the defect was invisible to quality checks…
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