For years, the client's customers complained about excessive dust in their polyester resin. The client asked us to fix it.
We started where most teams don't — with the measurement itself. Evaluating how they quantified dust in resin, we found the system too imprecise to trust. Working with industry experts, we developed a more accurate method and proved out its accuracy. Only then did we test dust levels at each stage of resin creation and pack-out, isolating exactly where it was generated. A series of tests pinpointed the fix: targeted improvements to dust filtration along the resin conveyor lines.
Filtration upgrades cut dust levels by 29% — a change customers could feel. And because the new measurement system flags any drift above benchmark, the client now catches problems before customers ever do. The fix won back major account-a relationship worth roughly $38M a year-that had started pulling orders.
