Capacity Optimization

Business Challenge

A large healthcare laboratory had implemented a new mission critical testing line, but it was unable to meet it’s quality or capacity targets.


The team conducted detailed workflow analysis on the testing line. Numerous studies and experiments were conducted to identify the critical variables affecting the line. Significant work was also conducted with the equipment manufacturers to troubleshoot issues and rule out possible root causes. Lean, Six Sigma and TOC tools were used to focus and create the solution design, optimize the capacity and balance the line.

Business Outcome

This project successfully increased throughput by 300%, generated $7MM in savings and had an ROI of 2 months.