Cost Deployment in Action – Structuring Losses under WCM
Client
Getrag Group, China
Date
March 15, 2019
Services
Cost Deployment | Sustainability & Resilience
Website
Major Improvments
- Full Loss Tree Mapping
Structured all losses into categories (Productivity, Quality, Energy, Logistics), creating a full WCM-aligned cost tree. - Data-Driven Prioritization
Used historical cost records and actual incidents to rank top contributors to total cost per unit. - Cross-Functional Deep Dive
Engaged production, finance, quality, and logistics teams in a joint analysis of root causes behind critical losses. - Deployment Board Setup
Built a visual board system to track top 20 cost drivers and link to targeted improvement projects.
Application Scope
- Machining Cell – Quality Loss Focus
Identified most frequent scrap causes and quantified financial impact using cost-per-defect indicators. - Assembly Line – Time Loss Analysis
Uncovered setup time waste and idle machine intervals, assigning monetary loss to each source. - Energy Cost Deployment
Deployed energy monitoring per station and linked excessive use to specific shift/time blocks. - Lean Budget Integration
Connected cost deployment results with the site’s lean annual budget and kaizen prioritization plan.
Customer Says
Success Projects

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Restructuring Production & Logistics in Heavy Gearbox Manufacturing
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National-Level Demonstration of Visual Transparency in Special Steel
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TPM & VSM Upgrade for Battery Quality Compliance
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