This project focuses on reducing PTFE coating waste in the Teleflex 10993PET3 surgical suture coating process. The current dipping operation generates substantial material waste due to excess coating solution being prepared and discarded after production, creating more than $10,000 in annual loss. The team is analyzing the existing process, measuring current-state waste, identifying root causes, and developing a practical improved coating method that reduces waste without negatively affecting product quality, throughput, or compliance with Teleflex manufacturing and medical-device requirements. The project’s success is defined by achieving at least a 50% reduction in coating waste volume per year and generating $10,000 or more in annual waste-avoidance savings.