This Six Sigma project tackled the problem of trucks sitting around too long at wind farm sites, racking up an average of $8,000 per delivery in detention and layover costs. The root cause was poor coordination and slow unloading. I used the DMAIC framework to lead a team in figuring out where things were breaking down. We rolled out a common-sense policy: unload the truck to a pad on-site and reload it right away if there's another component ready—either from the same turbine or a previous one.

That change cut costs by 35% in just 10 weeks. Each crew is now saving over $624,000 a year, and if this process were adopted nationwide, it could save the industry more than $584 million annually. It’s a simple fix that improved site flow, reduced wait time, and got everyone working together more efficiently.