Customer survey revealed significant and immediate improvements needed in quality and costs in the following areas:

• Custom color rejects
• Formula success rate
• Material loss
• Change-over rate
• Lead time
• On-time delivery performance

• Developed and implemented lean manufacturing
• Transferred knowledge and expertise of lean manufacturing to ensure sustainability for continued growth and improvement of their manufacturing process

• Total savings of $950,000 in a five-month period
• 60% reduction in custom color rejects
• 17% improvement in first-pass formula success rate
• $250,000 annual savings in raw materials
• 45% reduction in change-over time
• Reduction in lead-time from 12 to 5 days
• Improved on-time delivery from 87% to 98.5%