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Case Study
  • Quality
  • Open Access

Nailing Down a Solution

How design for Six Sigma helped solve a complex problem and reduced raw material costs

Publication:
Lean & Six Sigma Review
Date:
May 2022
Issue:
Volume 21 Issue 3
Pages:
pp. 9-15
Author(s):
Mateos, Matthew C.

Abstract

A manufacturer of roof shingles determined that the balance between filler and asphalt of its product was often wrong, wasting 2.75% of the asphalt overall due to faulty calibration of equipment. By adjusting the calibration procedure and frequency for the facility's nuclear magnetic resonance analyzer, analysts were able to help the facility more accurate read the composition of the filled asphalt mixture used in the shingles. In doing so, the facility reduced its material waste by 46.9% and thereby save $2.4 million in material costs per reporting period.

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