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In tough times, manufacturers focus on reducing their operating costs, but may not be able to afford to spend their way out by buying more productive machinery. With that pathway closed, what are the opportunities for radically reducing costs without replacing existing machines? This paper explores Productive Process Pyramid™ and the four areas where substantial savings can be found if firms are prepared to change the way they control their machining processes.

The Productive Process Pyramid provides a systematic approach to eliminating variation in machining processes. Without making any fundamental changes to the machining process, improved process control can yield substantial recurring cost savings through greater automation and lower quality costs. The level of investment required to implement such controls is relatively low, with a payback of just a few months. Eliminating variation from your processes will also increase the returns on any future capital investments that you make.

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