Haynes Lean Six Sigma Program

Mark Comerford, President and CEO of Haynes International, discusses the company's results and highlights its Lean Six Sigma program which is focused on delivering operational efficiency. Haynes improvement culture extends to the environmental discipline where its has driven energy cost savings. ...

... "We’ve also expanded the use of key metrics across our business focusing on cost reduction initiatives and extending our Lean and Six Sigma programs. During the year, we were also nominated for the 2009 Indiana Governor’s Award for Environmental Excellence, and we were recognized by Indiana Lieutenant Governor Becky Skillman, for environmental stewardship. Furthermore, working with Purdue University and US Department of Energy, we’ve taken on initiatives in our plants, which we estimate will result in savings of approximately $300,000 in annual energy costs. " ...

Via Seeking Alpha: Haynes International Earnings

More on the Haynes and Purdue collaboration ...

Purdue Manufacturing Extension Partnership project with Haynes International: "Haynes implemented a five-person Energy Savings Team to identify and implement energy savings projects ... Haynes expects to see natural gas cost savings of nearly $360,000 annually upon the completion of all the EES projects. "

Continuous Improvement of Energy Performance in Manufacturing

Can we create a manufacturing landscape that values the continual improvement of energy performance. There is collaborative work on developing white energy credits to create incentives for energy efficiency leadership. ...

... "Foster an organizational culture of continuous improvement in energy efficiency ... " ...

Via Superior Energy Performance: U.S. Council for Energy-Efficient Manufacturing

WABCO Lean Manufacturing Applications

WABCO, tier one supplier to commercial vehicle industry, is able to navigate challenging business conditions and achieve profit while revenue is off significantly. The company is applying lean methods to enable cost savings and is seeing some growth in emerging markets. ...

... "WABCO continues to anticipate and mitigate adverse market conditions through orderly cost reduction measures, systematic productivity initiatives and further applications of lean manufacturing, among other accomplishments that our people have honed over the years in our globally connected culture of operational excellence, said Esculier " ...

Via WABCO: Q3 2009 Results

NCI Builds Up Use of Lean Manufacturing Tools

NCI Building Systems sees profitability return after emphasizing cost reduction programs across its business segments. NCI is a large integrated manufacturer of metal products for the nonresidential building industry in North America. The Building segment deploys lean tools to improve its performance metrics and has reduced its manufacturing footprint. ...

... "Cost reduction programs, which began in November 2008, have resulted in the migration from 43 manufacturing facilities to 32. Overlapping and less efficient operations have been eliminated, and more automation and lean manufacturing tools have been utilized. " ...

Via NCI Building: Third Quarter Earnings Discussion (PDF)

Multi-Fineline Electronix Lean Six Sigma Quality Improvement Initiatives

Multi-Fineline Electronix is using lean and Six Sigma to drive its quality improvement and sustain its operating execution for targeted results. ...

... "We continue to execute ambitious lean manufacturing and Six Sigma quality improvement initiative. We are also continuing to engage our supply chain and cost reduction activities. The enhancements in our manufacturing and supply chain operations have by and large helped to offset the negative impact on gross margin, resulting from the recent product mix that has a higher material content, along with today's more competitive pricing environment, which has also put pressure on our gross margin. " ...

Via Seeking Alpha: Earnings Call

Lydall Lean Six Sigma Improves Operating Processes and Cost Structure

Lydall reports results from a challenging period where revenues and earnings have decreased markedly. The company is responding with a reduced cost structure through Lean Six Sigma and manufacturing footprint actions, while managing the business for cash. ...

... "Going forward in 2009, we anticipate the significant progress we have made in improving our business operating processes through Lean Six Sigma, coupled with the major cost reductions from the North American automotive consolidation, will improve the Company’s financial results as our markets begin to stabilize. " ...

Via Lydall: SECOND QUARTER (PDF)

Stepan Six Sigma Operating Cost Improvements Drive Profitability for Surfactants

Stepan sees revenue decline, but manages cash and profitability well through actions such as Six Sigma operational efficiency. ...

... "Surfactant segment gross profit rose by $12.8 million, or 38 percent, for the quarter and $19.7 million, or 30 percent, for the six months. The improved gross profit was due to declining commodity costs, purchasing led cost reduction initiatives, and lower operating costs due to the success of six sigma teams as well as restructuring activities at one production site. " ...

Via Stepan: Second Quarter and First Half Earnings

Ingersoll-Rand Lean Six Sigma Operational Excellence

Ingersoll-Rand has been challenged by the economic downturn with exposure to the construction market and the need to service a higher debt load related to acquisitions. Yet, the company is positioned in the HVAC market for infrastructure investments and has expanded geographically into Asian markets, where growth is expected. ...

... "IR has been using Lean Six Sigma for years, and will continue to rely on it to achieve operational excellence, which reflects IR's clear and constant awareness of efficiency and cost. " ...

Via Seeking Alpha: Ingersoll-Rand Excellence

Operational excellence is a key lever for the company in 2009. ...

Ingersoll Rand via Reuters: "We are realizing the synergies from the recent acquisition of Trane and from our initiatives in purchasing and Lean Six Sigma, which will produce even greater benefits in 2009. "

The company has invested in training programs. ...

Ingersoll Rand Lean Six Sigma Training Series.

IR has expanded its lean methods globally. ...

China Lean: "Ms. Zhang Dong is currently the Lean six sigma manager of Ingersoll Rand Industrial Technology Air Solutions, Asia Pacific. She has more than 14 years working experience in Engineering, Operations, Marketing and Service. "

Ingersoll Rand employees have had successful careers in industry, helping manufacturers become successful with Lean Six Sigma. ...

Mark Beffel Bio via APICS: "Mark has over 35 years experience in Manufacturing, Engineering, and Operations management with John Deere, Pentair, Lozier, Ingersoll Rand and Manitowoc. "

IR leaders are published in the field. ...

Leaning Into Six Sigma Book by Barbara Wheat via Barnes & Noble: "Barbara Wheat is the Director of Six Sigma for Ingersoll-Rand Tool and Hoist Division, where she brings the tools and techniques of both Lean Enterprise and Six Sigma together to institutionalize a world-class system of continuous improvement. "

SGL Six Sigma Benefits

Analysis of SGL Group's performance ... The company is expecting significant benefits from its Six Sigma efforts. ...

... "Cost reduction based on the six sigma initiative is calculated at EUR 26 mn. " ...

Via BolsaMania: Anaysis of SGL

Lean Is Easy to Grasp

While the concept of lean is easy to grasp, implementing it is a journey. Industry has yet to fully leverage its benefits. ...

... "At its most fundamental level, a lean approach to manufacturing entails just what you'd expect: stripping away the excess. Going lean means cutting costs and boosting efficiency at every stage of the manufacturing process. " ...

Via DC Velocity: Lean up your act

NBC Six Sigma Retooling

NBC is using Six Sigma to improve its processes in the TV network space and has positioned itself for a transformation versus its peers. ...

... "they are clearly retooling NBC in the Six Sigma spirit that parent General Electric pioneered - streamlining, cutting costs, and maximizing efficiency in every minute aspect of their production and distribution processes. " ...

Via Seeking Alpha: TV Networks

Six Sigma Spreads

Six Sigma and lean are spreading to non-traditional industries, such as aviation, pharma, and financials. ...

... "Finally, six sigma is also making gains in financial services however the focus here is on revenue enhancing projects and not just cost reduction initiatives ... " ...

Via The Manufacturer: Lean Six Sigma

The Lean Manufacturing Response

Downturn prompts local firms to accelerate lean manufacturing efforts. ...

... "Aside from idling their local factory, the leaders at Masco are looking to cut costs through lean manufacturing procedures that reduce waste and conserve energy. " ...

Via Ocala Star-Banner: Response to financial downturn

Standex Lean Manufacturing Initiatives Increase Operating Income

Standex reports excellent financial results buoyed by its efficiency programs. ...

... "We also continued to see steady top-line growth from our recently created Mold Tech texturizing operations in Turkey, Eastern Europe and China. The lean manufacturing initiatives we implemented in the past year, cost reductions and higher sales volume enabled us to generate a threefold increase in operating income in the quarter. " ...

Via Standex: Fourth-Quarter and Year-End Fiscal 2008 Financial Results

Footwear Lean Manufacturing Creates Efficiency

Footwear manufacturers drive operating efficiencies through the application of lean manufacturing techniques. ...

... "Adidas AG CFO Robin Stalker said the company was well situated: We believe we are extremely well positioned competitively, vis-a-vis our competitors, in terms of lean manufacturing and engineering of our product. " ...

Via Footwear News: Crisis

Wausau Paper Lean Six Sigma Cultural Approach

Wausau Paper discusses its lean and Six Sigma approach in the enterprise during its earnings call with analysts. Its Lean Six Sigma implementation varies across the lines of business. ...

... "Where we have technical problem solving issues as it relates to high performance grades and specialty, you might see a Six Sigma approach with respect to broader cost reduction opportunity, you might see a lean approach being used and sorry to tell you it somewhat differs necessarily from one business to the other but it tends to be a continuous and intense cultural approach within the corporation. " ...

Via Seeking Alpha: Wausau Paper Corp. Q4 2007 Earnings Call Transcript

Travel Management Efficiency Through Six Sigma

Travel manager uses Six Sigma to drive efficiencies in the travel management process and reduce overall travel costs. ...

... "Using the Six Sigma analytical process, Kelliher determined that these cancellations and exchanges were significantly bulking up Dominion's air costs. " ...

Via Business Travel News: 2007 Travel Manager Of The Year

Healthcare Cost Efficiency Using Lean Six Sigma

Hospitals see Lean methods as answer to rising costs. ...

... "We have a process called Lean Six Sigma, she said. Basically we look at hospital processes to see where we can improve quality by becoming more efficient. " ...

Via Cumberland Times: Hospital Costs

Cost Reduction Program Yields Results

Standard Register implements cost reduction program to compete effectively in its industry. ...

... "Earlier this year, the Company consolidated its manufacturing and warehousing operations in a move expected to save approximately $5 million annually. Today's action eliminated approximately 250 positions, primarily in management and overhead, representing $22 million annually in compensation and related costs. Other new initiatives that target purchasing costs and other non-compensation expenditures are expected to lower costs by an additional $13 million annually. These actions, including the earlier restructuring, are expected to reduce second half 2007 costs by $15 million versus the levels incurred in the first six months of the year. The remaining balance of the $40 million in annual savings is expected next year. Separation costs associated with today's restructuring are estimated at $3.5 million, which will be recorded in the third quarter. " ...

Via Standard Register: Cost Reduction

Goodyear SixSigma Cost Savings Ambitions

Goodyear increases cost-savings targets in an ambitious plan to transform the company's profitability, through Six Sigma and other creative methods. ...

... "Based on the significant progress we made in 2006 against our four-point cost-savings plan, I am confident we will exceed our 2008 target of more than $1 billion, Keegan said. We are aggressively targeting additional cost savings in 2009 and raising our gross cost savings goal over this four-year period to between $1.8 billion and $2 billion. " ...

Via Goodyear Tire: First Quarter Results Provide Platform for Growth, Cost Savings

Value Engineering Award to Northrop Grumman For Lean Principles

Northrop Grumman is selected by U.S. Department of Defense to receive its Value Engineering Achievement award for innovative productivity improvements, that leverage the principles of Lean Six Sigma. ...

... "Value Engineering, developed in the 1940s at General Electric Co., is a systematic process widely used in government and industry to identify actions that improve performance, reliability, quality, safety and life cycle costs. The Defense Department said a total of 3,473 government and contractor-initiated proposals were accepted during fiscal year 2006 with projected savings/cost avoidance in excess of $1.6 billion. Northrop Grumman was nominated for its Value Engineering Achievement award by the Defense Contract Management Agency (DCMA), which cited the implementation of Six Sigma and Lean principles at the company's Integrated Systems sector. According to the DCMA nomination, Northrop Grumman's implementation of these initiatives has been increasingly reducing costs, improving quality, enhancing effectiveness and increasing efficiency throughout the enterprise and on Defense Department weapon system acquisition contracts and services. The 2006 Defense Department Value Engineering awards will be presented May 16, 2007 at the Pentagon. " ...

Via Northrop Grumman: Northrop Grumman to Receive U.S. Department of Defense Value Engineering Award for Improving Productivity

Nortech Strategic Focus: Lean Manufacturing Initiative to Drive Significant Profit Margins

Nortech Systems reports 17 percent increase in quarterly net sales and an increase in annual net income. The company is initiating a lean manufacturing program to continually improve operational efficiency resulting in expansion of profit margins. ...

... "During 2006, Degen said higher costs for energy and commodities were offset by volume increases and operational leveraging. Another strategic focus for Nortech is the launching of a comprehensive lean manufacturing initiative aimed at further cost reductions and continual improvements. This program has a near-term goal of increasing the company's net profit significantly. As with lean manufacturing efforts, Nortech will continue to focus on building customer relationships that will permeate every aspect of the company, not just sales and customer service. While strengthening its relationship with existing customers, Degen said the company continues to gain traction both with new customers and new markets. " ...

Via Nortech: Nortech Systems Reports Fourth Quarter, Fiscal 2006 Year-End Results ...