It is hard to tell whether a particular fix works without knowing where waste occurs. Start with records that can be weighed and classified within your operation.
Use the same fields for each loss
Record date, product or lot, discarded quantity, process step and reason code. In distribution, separate damage, waiting, reading deviations and return reasons; if the cause is unknown, mark it for investigation rather than guessing.
Choose one cause and run a trial
Select a recurring major loss and define one change, such as delivery order or container layout. Compare discarded quantities before and after for the same period and product scope; also check service and product suitability.
