ByGeorge TanineczAt A Glance
- Productivity increased 65% in five years.
- Since 1990 a 50% increase in production without added square footage.
- Manufacturing cycle time for Sawzall product reduced 97%.
- Order-to-shipment leadtimes for all products is two days, down from five months.
- Reduction in scrap/rework of 48.6%.
- First-pass yields of 97.7% for all finished products.
- Product-development cycle time dropped 35%.
- Warranty activity per unit shipped reduced 48% even though company maintains a 30-day no-questions-asked return policy.
- Safety performance improvement of 65%.
- 100% of production workforce in self-directed work teams.
- On-time delivery of 98% based on date customer requested.