Cutting Waste in Corrugated Packaging: A Lean Six Sigma Approach
In the high-volume world of corrugated packaging, even small inefficiencies can add up quickly. This Green Belt Lean Six Sigma project targeted waste at the dry end of the corrugation process, where sheets are cut and stacked, cutting scrap from 1.9% to just 1.33%. The result? An impressive $50,000 in estimated annual savings. By combining data analysis with frontline insights, the team standardized machine settings, implemented preventive maintenance, and aligned operator practices across shifts. Tools like Fishbone Diagrams, FMEA, and Process Capability Analysis helped expose the root causes, while real-time dashboards ensured ongoing accountability. More than a cost-saving initiative, this project boosted team motivation and built a culture of continuous improvement. It’s a strong reminder that structured, data-driven problem-solving isn’t just about fixing issues, it’s about creating lasting value.