Situation: A paper product manufacturing company needed to reduce expenses while increasing output in order to remain competitive. The production machinery used in its process is 120 ft long and required considerable manpower to change over between jobs. Set up time for a new job could be as long as eight hours.

Solution: The manufacturing process was filmed in detailed and reviewed frame-by-frame for wasted motion.

Result: The team identified ways to eliminate 135 steps in the set up process and reduce change over from an eight hour process to one hour and eight minutes.