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Practical thinking for plant managers, operations leaders, and CEOs responsible for protecting margin in plastics injection molding.

No theoretical frameworks. No MBA-speak. Just hard-won observations from 30+ years on the manufacturing floor — and what they mean for your margin.

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Case Study

Cutting Scrap, Boosting Profits: How a Simple Analysis Transformed Manufacturing Efficiency

Jim Chapman  ·  August 2024

A client was running a 9-pound Class A part through a two-cavity mold at 30,000 units annually — with a scrap rate exceeding 20%. The fix turned out to be less about the process and more about how people were making decisions.

  • Scrap rate reduced from over 20% to consistently below 5%
  • Root cause was inspector inconsistency, not process failure
  • Attribute Agreement Analysis aligned all stakeholders on pass/fail criteria
  • Direct positive impact on margin with no capital investment
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