Uptime Improved Carton Machine
In just six months, a Lean Six Sigma Black Belt project transformed operations at a consumer goods packaging facility, delivering over $33,000 in monthly savings. By targeting excessive downtime across all carton machines, the team improved machine efficiency from 99% to 110% and cut downtime from 12% to just 4.5%. Key to success? A skilled cross-departmental team, data-driven root cause analysis using tools like the Pareto Diagram, and a hands-on coaching strategy to shift operator habits. This case study shows how Lean Six Sigma’s DMAIC method doesn’t just optimize processes, it creates lasting cultural and financial impact. Whether you're new to Lean Six Sigma or considering your next project, this is a standout example of how focused teamwork and continuous improvement can lead to measurable operational excellence.