Having analysed all of the above costs, the Lean tools outlined earlier led to the team implementing numerous improvements to the process including new data sheets, Poka Yoke / ANDON application, 5S implementation and operation involvement. The benchmark costs of re-work at 10.23% equated to £325,000 per annum. Following implementation of all the improvements, the team has achieved a reduction in re-work from 10.23% to 6.65% which equ

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