Continuous-Flow manufacturing has had a dramatic impact on Knight Dental Lab’s bottom line, quality and communication. Rob Fletcher (pictured here with Barbara Warner Wojdan) has more goals to hit, like converting the lab’s shipping and invoicing department into a line format and adding more shifts so the lab can achieve a one-day crown. — tagged Barbara Warner and Robert Fletcher

In the past, the lab typically had 2,000 cases sitting on carts waiting to be processed. Today, Knight technicians work in four U-shaped production lines—with model and die at one end (far left) and seating and finishing on the other (far right)—and continuously feed each other work.