Background - Supplying batch specific JIT leaves no margin of error for defect parts stop the line. Morland manufacture from timber products that have a raft of naturally occuring inconsistencies, e.g knots that are impossible to avoid.

The Problem - Morland needed to achieve a rejection rate of better than one in a thousand parts.

The Solution - Morland looked at rejection data over 12 months and realised that human error was the cause of 65% of rejections and handling damage a further 20%. The causes of the human error were broken down into manageable areas. EG Colour selection  was a small but constant error so colour charts were installed at the point of control to advise operators of the right colours.
 
By tackling each area in turn the human errors were eradicated and handling damage was reduced by packaging refinements.
 
In 2008 Morland has recorded less than one defect per thousand and 100% on time delivery.