Employees have done more than cut lead times by 62 percent and improve on-time delivery by 42 percent. They’ve made scrap and rework nonissues, improved safety by modernizing layouts and tightened quality control with in-process checks replacing an end-of-line inspection.

Order-driven production has boosted job satisfaction. “Managing ourselves makes a lot of sense. We know the line has to be empty by the end of the day, and how we do it is left to us,” says team leader Roland Schmid.

Customer trust is improving, too, as Weinstadt keeps its delivery commitments even as it keeps cutting lead times. Customers used to place larger-than-needed orders as a hedge against late delivery. Now they trust the plant’s recommended lot size of 200 items or less for optimal workflow.