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Rapid Action Team Results

Using Rapid Action to Reduce Rework on the Plant Floor

Lean Six Sigma
A Fortune 500 paper manufacturer was finding it difficult to avoid costly rework and errors when modifications and change orders were submitted on existing projects, a problem uncovered by routine audits. By engaging those close to the work with Rapid Action, they reduced rework by 5% and saved the company hundreds of thousands of dollars…all in less than 60-days.


Routine audits identified serious non-compliance with modification and change order policies on existing projects leading to costly rework and dissatisfied customers.

Team Engagement Strategy

A frontline team of employees who work with MOD orders every day was engaged to brainstorm ways to improve the process. Equipped with Rapid Action, a process for solving problems quickly through teams, they were able to sort and act on their best ideas to see substantial gains in less than 60-days.

Rapid Action Project Charter

How can we improve the process for auditing Modification work orders in order to increase compliance, reduce rework, reduce the risk of injuries and increase safety awareness?

Sample Solutions Implemented

  1. Developed a flow chart and standardized checklist template for a MOD work order.
  2. Created a specific MOD work order team with electronic record-keeping capability.
  3. Developed a training, communication and compliance plan to ensure 100% compliance with new policy.

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Rapid Action's powerful toolkit has helped hundreds of organizations achieve measurable results in less than 60 days while getting their team members engaged in long-term improvements. Download a Rapid Action Project Planner and see where you could be in 60 days!
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