Reducing scrap and rework is a modern manufacturing imperative that requires a proactive, strategic approach focused on four key pillars: process optimization, quality control, technology integration, and operator training and empowerment.
SUMMARY: Reducing scrap and rework is a modern manufacturing imperative that requires a proactive, strategic approach focused on four key pillars: process optimization, quality control, technology integration, and operator training and empowerment. By moving away from reactive, manual methods and embracing real-time data from tools like SPC software, manufacturers can prevent defects before they occur. This eliminates the significant costs associated with wasted labor and materials, streamlines operations, improves audit processes, and enhances overall profitability. The approach turns data into actionable knowledge, making quality a fundamental part of the business rather than just a final inspection.
Scrap and rework are generally consequences of a production run; they are symptoms of a process that is not fully controlled.
Scrap is a significant drain on a company's resources, including
The costs can be staggering, as seen by client McCormick Flavor's experience, where a tiny reduction in overpack significantly impacted their bottom line. This proactive mindset is a hallmark of a modern, efficient operation.
Here’s a guide you should consider when trying to reduce your scrap and rework in your manufacturing plant.
Blurb:“GainSeeker has helped us reduce material costs by 10-30% annually. Of all the plants in the McCormick Flavor Division, our plant is consistently at the top of the list for efficiency of material usage, and by a substantial margin. We trace that directly back to our use of the Hertzler software.” John Campbell, Quality Manager
Process optimization involves analyzing and refining manufacturing processes to achieve maximum productivity and quality while reducing waste and costs. The goal is to make a process as fast and efficient as possible while eliminating excess waste.
SPC helps you “listen” to the data to understand what your equipment is truly capable of producing. One quality manager from McCormick Flavor Division noted, "We've achieved reductions of up to three-tenths of a gram across all our fill lines.”
This process optimization, made possible by GainSeeker's control charts, led to massive savings as they learned to adjust the process closer to their target fill weight. This is best for processes like precision blending, where the right ingredient quality is key to preventing spoilage reduction.
Process optimization also involves identifying and challenging arbitrary specifications that lead to unnecessary waste. The same quality manager notes, "All too often, the variation that our designers allow us is completely arbitrary" and has no discernible impact on the product.
By understanding a process's actual operating range, a company can work with designers to reset limits that are both realistic and cost-effective.
This saves you money by reducing the amount of product that would otherwise be wasted on tablet coating issues, mold rework, and resin usage.
While quality assurance aims to prevent faults by overseeing the development process, quality control is a proactive approach that involves identifying and addressing defects as they occur. It's about ensuring a specific quality standard is maintained during production.
In 2025, quality control will no longer be a reactive process of inspecting finished products. Instead, it will be about real-time monitoring and immediate intervention. It's about maintaining a specific quality standard during production, which is crucial for achieving part fitments and preventing issues like paint defects.
SPC software, like GS Premier and GainSeeker Suite, provides instant notifications when a process drifts out of its controlled limits, allowing an operator or engineer to intervene before defects are created.
The quality manager at McCormick's noted that having their system online and available for audits "lets him know we have nothing to hide".
Quality control is necessary to prevent rework and the associated costs. By catching abnormalities early, companies can rectify minor deviations promptly, ensuring consistent quality and reliability with minimal variation.
As one of our industry experts notes, "rework costs at each stage of the assembly process will be 10 times greater than at the previous stage."
Manufacturers can avoid this escalating cost by stopping issues at the source, especially when they need to rework soldering and rework components.
Effective scrap and rework reduction hinges on seamlessly integrating different technologies and systems. This is about blending tools to function as one cohesive unit, moving from isolated islands of capability to a connected continent of possibility.
Technology integration starts with automated data collection, which eliminates the high cost and human error associated with manual data entry. A food manufacturer used automated data collection to "streamline and reduce these costs."
By connecting machines and sensors throughout the production process, manufacturers can gather and analyze vast amounts of data to improve efficiency.
According to one of our experts, this data can be used to track a few "bell-weather checks on every batch" to "respond to special events and only perform testing when needed."
Operators are on the front lines of manufacturing, and their skills and awareness are vital for quality control and efficiency. A modern approach to reducing scrap must include a focus on training and empowering the workforce.
Effective training programs for manufacturing employees enhance production efficiencies and make them less prone to mistakes.
These programs provide a strong foundation in manufacturing processes and quality control, ensuring workers can perform their tasks safely and accurately.
A data-driven system not only automates tasks but also augments the workforce, empowering them to focus on value-added activities. When operators have real-time access to information and understand how to use SPC tools, they are empowered to take ownership of their processes and intervene immediately to prevent defects.
This cultural shift, where a data-driven system becomes "core to the way we do business," is essential for long-term success. Read more about the impact of a skills development culture on achieving operational excellence.
Manufacturers can significantly reduce scrap and rework by adopting a data-driven strategy and embracing the four pillars of process optimization, quality control, technology integration, and operator empowerment.
Our clients have used solutions like GainSeeker Suite and GS Premier to achieve a 10-30% reduction in material costs and overall waste. You can also achieve this level of efficiency. Talk to one of our experts, and we'll help you every step of the way to turn your data into knowledge and your waste into profit.
Reviewed by Phil Mason, MBA (31 July 2025): Phil has been the VP of Business Development at Hertzler Systems Inc. since January 2010. Previously, Phil was an Adjunct Professor at Green Mountain College (until Jun 2018), Associate Professor at Goshen College, Executive Director Adult/Graduate Programs at Goshen College (Jul 2015-Dec 2016), Assistant Professor at Bethel College (from Aug 2011), Business Development at Digitec, Inc. (Oct 2008-Nov 2010), Regional VP at Mennonite Mutual Aid (Sep 2001-Feb 2008), and General Manager at Ikon Technology Services (from Jan 1999).
Links: [LinkedIn] [Quality Magazine] [FinalScout]
