Department of Defense Lean Six Sigma Software Enabler

The U.S. military standardizes on Minitab statistical software to support its implementation of quality improvement methods using Lean Six Sigma. ...

... "Since the U.S. Army deployed Lean Six Sigma in 2005, nearly 2,000 personnel have been trained, more than 1,000 projects have been completed, and more than 1,600 remain active. The Army credits these projects with achieving nearly $2 billion in savings so far. The Department of the Navy has trained more than 5,000 sailors and Marines as Six Sigma green or black belts since 2006. The Navy estimates savings from its projects for 2006 and 2007 to be $450 million, a 4-to-1 return on investment. The U.S. Air Force has trained more than 500 Six Sigma belts, and its Air Logistics Centers received two Shingo Prizes for quality improvement last year. The Air Force has committed to a 40,000-manpower reduction without impairing its operational capabilities due in part to efficiencies gained from its initiatives. " ...

Via Minitab: Minitab quality improvement software

Six Sigma Measurement Systems

Understand how your customers measure success and position your product or service to exceed their expectation in a differentiated way. Be prepared to offer the associated metrics. ...

... "If their company is involved in Six Sigma or other quality-type initiatives, measurement is an integral part of their operations. Your job is to uncover the existing metrics. That means you need to ask about what they track and how they measure results. " ...

Via 4Hoteliers: Value Proposition

Lean Six Sigma Project Challenges

Six Sigma discipline takes time to adopt and perfect. A more holistic approach to process improvement may be needed to position Six Sigma and lean properly. ...

... "There is rising concern across multiple industry sectors regarding the failure of many internally led 6s / lean projects, so much so that we must explore why so many initiatives do not reach their desired results ... " ...

Via Supply and Demand Chain: What Went Wrong?

Huttig Lean Manufacturing Initiative

Huttig Building Products reports net loss of $9.8 million for the 2008 first quarter compared to a net loss of $3.4 million in the corresponding year ago quarter. Net sales also declined by 25%, as the company adjusts its business strategy to seek efficiencies and conserve capital through lean methods. ...

... "Looking ahead, Huttig is implementing a LEAN manufacturing initiative to identify additional opportunities to improve production and operational efficiencies. The Company is also intensifying its efforts to sell slower moving inventory to free up capital and reduce debt. " ...

Via Huttig Building Products: First Quarter 2008 Results

Laboratory Six Sigma

Hospital laboratory uses Six Sigma to drive its efficiency initiative. Cycle times for testing are decreasing. ...

... "The lab is also using the principles of Six Sigma, a system meant to help companies eliminate defects that has been embraced by General Electric and other manufacturers. " ...

Via The StarPhoenix: Saskatoon Health Region

Lean Manufacturing Enables Xerium Growth Program

Global manufacturing company, Xerium Tech, supports the paper production industry with products and reports its financial results. It is executing a turnaround plan that includes lean manufacturing to lay the operational efficiency foundation for its strategic growth plan. ...

... "These growth program costs for the year ended December 31, 2007 include expenses incurred for our lean manufacturing initiatives, expansion into Vietnam and other growth programs. " ...

Via Xerium Technologies: Fourth Quarter and Fiscal Year 2007 Results

Operational Turnaround through Six Sigma Excellence

Vertis Communications reports its fiscal results and describes its turnaround plan which includes the use of lean and Six Sigma methods to drive operational excellence. ...

... "The Company implemented a turnaround plan in early 2007 involving new management and a multi-faceted turnaround strategy that includes:

1) gaining a better understanding of customer's expectations and a commitment to exceed those expectations via our Customers Delight Initiatives;

2) establishing a platform of operational excellence driving improved quality, service and efficiency via a re-engineered manufacturing system based on lean and six sigma; and

3) enhancing management processes throughout the Company.

The turnaround initiatives are beginning to show results ... " ...

Via Vertis Communications: Vertis Reports 2007 Fourth Quarter and Full-Year Results

Six Sigma Quality Improvement Spurs Growth

Workforce involvement in quality initiatives drives company growth. The free flow of communications keeps the improvement ideas fresh, exciting, and meaningful to the current business dynamics. ...

... "Taylor, now president and CEO, mandates that each of his 160 employees participates in quality systems, sounding-board meetings and the continuous improvement of the company. This team-based initiative has led to revenue growth of 10 percent in each of the past five years. " ...

Via Smart Business: Wright Tool Co.

Lean Manufacturing is Music to their ears

Musical instrument manufacturing benefits from a dose of lean, as the workforce is educated on the principles and techniques. ...

... "But D'Addario's bigger plan to increase profitability lies in his Toyota-inspired lean manufacturing initiative. The company is putting 12 employees, who volunteered to become lean champions, through about 400 hours of training ... " ...

Via Newsday: Reinvention

Lean Manufacturing Excellence Recognition for Medical Diagnostics Company

Ventana Medical Systems is awarded the National Award for Manufacturing Excellence from the Association for Manufacturing Excellence (AME). The award is in recognition of the utilization of strategies and techniques that improve competitiveness and profitability. ...

... "We are very proud to be the recipient of this award, which places us as a leader in lean systems methodologies regionally, nationally and within the diagnostics industry. Our lean manufacturing initiatives, which are supported by a culture of continuous improvement, are just one of the many ways we strive every day to constantly improve upon quality, productivity and profitability throughout all levels of our global organization. " ...

Via Ventana Medical Systems: Ventana Medical Systems to Receive National Award for Manufacturing Excellence from the AME

Boeing Lean Manufacturing a Differentiator

Boeing wins Air Force contract for maintenance. ...

... "Using Lean manufacturing, and employee involvement initiatives, we have reduced the number of days the aircraft are out of service for maintenance by 19 percent, cutting costs by 15 percent per aircraft. " ...

Via Aviation Week: Boeing Success

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

Regal Beloit Earnings Driven By Lean SixSigma

Regal-Beloit sees growth and sustains profitability through Lean Six Sigma, which helps the company increase margins. Regal-Beloit uses GE Six Sigma methods. ...

... "The Company's initiatives continued to gain traction and had a significant impact on the Company's performance. New products and acquisition growth fueled sales growth, while Lean Six Sigma helped support operating margins. Net sales increased 5.1% to $418.6 million from $398.3 million in the first quarter of 2006. " ...

Via Regal Beloit: 11% Earnings Per Share Increase on Strength of Industrial Markets

Lean Principles Part of Global Competition

Mexico manufacturing site builds infrastructure to compete globally on the shoulders of lean principles. ...

... "The company now puts more focus on product sectors and industries where there is a competitive advantage, such as enterprise computing and storage, medical, auto-motive, multimedia, industrial and communications. It also employs Lean manufacturing initiatives. " ...

Via Electronics Supply and Manufacturing: Mexico Electronics Manufacturing

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 ...

LeanSixSigma ProfitMargin Improves: Regal-Beloit

Regal-Beloit sees bottom-line impact from Lean Six Sigma initiatives. Its profit margin is increasing from the operating efficiencies created by Six Sigma projects. The CEO reports that the earnings improvement is largely driven by contributions from corporate wide initiatives. REGAL-BELOIT CORPORATION is a leading manufacturer of mechanical and electrical motion control and power generation products. The company is headquartered in Beloit, Wisconsin. ...

... "The gross profit margin for the fourth quarter of 2006 was 24.3%, which was 150 basis points above the gross profit margin in the fourth quarter of 2005 as a result of contributions from our Lean Six Sigma and productivity initiatives. Income from operations was $39.5 million or 10.8% of sales, a 3.1% increase over the $38.3 million or 10.2% of sales reported for the fourth quarter of 2005." ...

Via Regal-Beloit: REGAL-BELOIT Fourth Quarter Earnings Per Share Increase 8%

Defense Lean Manufacturing Initiative

General Dynamics weapons manufacturing has accelerated, given world events. The company emphasizes efficiency with lean manufacturing as its foundation. ...

... "And in the last few years, they've begun to use the equipment in smarter ways, through lean manufacturing initiatives. For example, the company has gone to manufacturing cells - where a variety of jobs are performed on parts in a concentrated area, " ...

Via Maine Today: Defense Manufacturer Lean Initiatives

Six Sigma Statistics Software: Minitab New Release

Minitab releases version 15 of its flagship statistical software. This release contains a number of enhancements, such as expanded Gage R&R capabilities, power curves for power and sample size, and probability distribution plots. ...

... "Although Minitab is widely known for being easy to use, it contains the advanced tools needed for even the most rigorous quality improvement projects. That combination has fueled the software’s success, and Minitab has been used to implement virtually every major Six Sigma initiative around the world. " ...

Via Minitab: MINITAB LAUNCHES RELEASE 15 OF MINITAB STATISTICAL SOFTWARE

5S Effort: Lean at Moyno

Moyno implements lean manufacturing initiatives to achieve profitability through cost savings and to attract and retain highly skilled employees. ...

... "The 5S efforts of the lean manufacturing program involve five specific areas of focus: sort, set in order, shine, standardize and sustain. At Moyno, 5S is being implemented in six areas including, for example, the chrome plating area, the small pump area and the office area. " ...

Via Impeller: Lean Manufacturing Initiatives Increase Efficiencies at Moyno ...

Improve Customer Service: Lean Initiative ...

Hawk focuses benefits of lean manufacturing on customer service levels. ...

... "We have continued to focus on a number of lean manufacturing initiatives at our friction products and precision components segments to improve our level of customer service. " ...

Via HAWK Corporation: Hawk Announces Third Quarter 2006 Results

LaZBoy Lean Manufacturing Initiative ...

LaZBoy receives support for transformation of its workforce to lean methods, which sustain its global competitiveness. ...

... "Stegeman said the cellular, or lean manufacturing is a move away from the old production-line way of doing things at the Newton plant. " ...

Via The Newton Record: La-Z-Boy going to lean manufacturing ...

Government Kaizen Initiative

Local authority uses kaizen methods to improve services and their success is recognized. ...

... "Following recognition at national level, Aberdeenshire Council's Kaizen initiative is now a beacon of excellence across Europe after taking an international award for continuous improvement.

The Aberdeenshire approach on this theme is based on the Kaizen model. Kaizen is a Japanese expression meaning making something as good as it can be and the process engages teams of employees in concentrated blitzes to identify more efficient ways of working. The exercise has been driven by Chief Executive Alan Campbell and his Senior Management Team since 2004, and is supported by facilitators in all of the council services and Kaizen Champion Pat Browne. For each blitz undertaken, a team leader is appointed and in turn selects a team of between 10 and 14 people who are close to the process to be improved. " ...

Via Aberdeenshire Council: Aberdeenshire Blitzes competition to take European award ...

Sustain Profit through Lean Initiative ...

Material Sciences Corp leverages Lean Manufacturing initiative to weather the storm in a declining sales environment. ...

... "Clifford D. Nastas, chief executive officer for Material Sciences: However, despite the sales decline, our lean manufacturing and quality improvement initiatives implemented last year, combined with higher scrap prices, enabled us to sustain gross profit. " ...

Via Material Sciences Corp: Material Sciences Corporation Announces Second Quarter Fiscal 2007 Results ...

TPM Total Productive Maintenance: A Challenge

Incentivize your total productive maintenance initiative to position for success with computerized maintenance management systems. ...

... "Implementation of any major change such as Lean, Total Productive Maintenance (TPM), Reliability-Centered Maintenance (RCM) or a new CMMS can be difficult at best, especially given industry's dismal track record of success. " ...

Via Plant Services: Incentive-based CMMS implementation ...

Kaizen Delivery Improvement Recognized by Toyota ...

Toyota recognizes the Hub Group for reducing its variability in on-time delivery. Hub's achievement in delivery improvement is celebrated by Toyota with its Kaizen Challenge Award. The two companies worked collaboratively to enable this accomplishment. ...

... "Hub Group, Inc. has been awarded Toyota's prestigious North American Parts Operations (NAPO) 2006 Kaizen Challenge Award. Kaizen is a critical component of the Toyota Production System (TPS) management practice, and this award recognizes Hub Group not only for its ability to work in partnership with Toyota management, but for significant performance and efficiency improvements achieved in product deliveries to Toyota's U.S. Parts Delivery Centers (PDCs) across the country.

The kaizen team, comprised of both Hub Group and Toyota professionals, was able to significantly reduce bunching (the tendency for inbound container volumes arriving at PDCs to fluctuate unevenly throughout the week), improve on-time performance (from not-late to not-late and not-early), and to reduce costs by eliminating rail detention and storage for the Toyota PDCs. As a result of the success of this initiative, additional Toyota PDCs have been added to the program. Since Kaizen is a continuing process, further improvements will be explored and documented throughout Toyota’s PDC system. " ...

Via Hub Group: Hub Group Earns Toyota 2006 Kaizen Challenge Award

Hub Group, Inc. is a leading asset-light freight transportation management company providing comprehensive intermodal, truckload brokerage and logistics services.

Kaizen Events: Employee Involvement ...

Metaldyne involves their workforce in continuous improvement through kaizen events. ...

... "In addition, employees participated in 26 Kaizen group events in 2005 to improve all aspects of the operation. Another key driver was a preventative maintenance initiative in each department. " ...

Via Inside INdiana Business: Indiana Companies Honored For Productivity ...

Training Opportunity: Six Sigma Process ...

Funding grants are available for Six Sigma process improvement training ...

... "Business services and healthcare organizations are also encouraged to apply for funds to train employees in process improvement initiatives such as lean manufacturing, ISO and Six Sigma. Organizations in these industries can request up to $25,000 per application for training that can be completed in 12 months or less. " ...

Via Democrat & Chronicle: Business

Via ETA: Secretary of Labor Elaine L. Chao Announces $195 Million for President Bush's Competitiveness Agenda: "The goal of the WIRED initiative is to transform regional economies by enlisting the skills of the numerous and varied players in those economies to research and produce long-term strategic plans that prepare workers for high-skill, high-wage opportunities in the coming years and into the next decade. "

Lean Journey: Factory Work Cells ...

AMCO receives grant to enable workforce training in lean manufacturing. Their journey to lean involved redesign of factory into dedicated work cells. ...

... "AMCO Water Metering Systems Inc., a leading provider of innovative metering products and solutions received approval from the Incumbent Worker Training Program (IWT) for $20,000 in grant monies to be used to train their workforce in Time Wise Principles of Lean Manufacturing. Located in Ocala, Florida, AMCO Water is part of the Elster Metering Group, the world's largest multi-utility metering company for water, electricity and gas metering. Despite having a comprehensive portfolio of advanced metering products and meter reading solutions, AMCO knew that in order to continue to grow its position in the market, operational improvements were needed.



AMCO's journey began in April of this year with a change in leadership when Blake Snider became President of the company. Snider quickly realized that in order to sustain the company's growth, the business needed to embrace Lean Manufacturing; an initiative focused on continuous improvement and elimination of waste. John Bankey at the Florida Manufacturing Extension Partnership (MEP) was brought in to begin training the AMCO team in the Principles of Lean Manufacturing. " ...

Lean Journey: Factory Work Cells: Via Yahoo Finance: AMCO Awarded IWT Grant to Help Offset Training Costs ...

Lean Transformation: Ohio Growth Position ...

Manufacturing companies that have survived the downturn, through tranformation to lean practices, are in position to benefit during the current economic growth. ...

... "The region's survivors have learned to use the principles of lean manufacturing, which apply to small companies as well as big producers, said Steve Gage, president of MAGNET, a business consulting firm in Cleveland. Survivors have learned to differentiate themselves from competitors and to meet tight production schedules, he said. " ...

Lean Transformation: Ohio Growth Position: Via Beacon Journal: Stealthy success

Ohio has also benefited from a tax friendly business environment ...

OMA | Manufacturers Gather To Discuss State Policy: "Since the tax reform package was passed last June, companies around the state have announced plans for expansion and relocation. According to the Ohio Department of Development plans for new pharmaceuticals and metal products manufacturers and multi-million dollar expansions in numerous other companies in the state can be directly attributed to the state's new tax policy. "

Ohio manufacturing consortium forms Magnet ...



Magnet :: Manufacturing Advocacy & Growth Network: "Approximately 75 manufacturers from fifteen Northeast Ohio counties, as well as representatives from the Greater Cleveland Partnership, CAMP, Team NEO, NorTech and many others, spent more than a year developing a plan of action for manufacturing in Northeast Ohio. "

Ohio Department of Development supports business investment ...

Ohio Department of Development: STATE RECEIVES 60 APPLICATIONS FOR JOB READY SITES PROGRAM: "The JRS Program is a competitively funded program and was part of the $2 billion public works and economic development bond package initiative that was supported by Ohio voters last fall. The program will provide $150 million in grants to eligible and qualified applicants across the state, which are interested in developing job ready sites. There are five large-scale, high-impact project site categories that are eligible for funding under the program.



These categories include: mega manufacturing operations; technical center/research laboratories; manufacturing facilities; existing industrial buildings; and smart office complexes. Within three years after receiving a grant award, approved projects must receive certification from a third-party firm to verify the site has the necessary attributes to accommodate largescale end use development; the property will then be added to a statewide inventory of available sites. "

Lean Army Management Initiative ...

Army increases its efficiency with Lean Six Sigma ...

... "The new Army management initiative is Lean Six Sigma, said Holzinger and other Baumholder officials. Under Lean Six Sigma — two programs borrowed from corporate giants such as Motorola and Toyota – all employees are charged with thinking of ways to increase efficiency and cut costs. " ...

Lean Army Management Initiative: Via Stars & Stripes: Baumholder seeks ways to trim costs, increase efficiency ...

Kaizen Accelerates Production ...

Kaizen quality initiative complements Christie's production acceleration. ...

... "As part of its aggressive expansion in manufacturing capacity, Christie is also hiring additional technical and administrative staff that includes electronics, mechanical and optical engineers, technicians and industry experts. Christie has also implemented rigorous in-house educational and training programs designed to further maximize efficiency levels, streamline production, and deliver quality control standards that are among the highest in the industry. This includes an extensive global quality initiative and continuous improvements through Kaizen practices to ensure consistent conformance to customer expectations, while maintaining the highest standards of quality. " ...

Via Christie: Christie Ramps Up Projector Production as Digital Cinema Contracts Surge Worldwide ...

Lean Six Sigma Supports Joint Venture ...

Adam Cort explores the success of Lean Six Sigma at an exemplary plant in the UK ...

... "Then came CAT's 2001 Six Sigma initiative, whereby the company mandated that operations worldwide would adopt the methodology. According to Clark, Six Sigma helped Perkins Shibaura focus its quality efforts. " ...

Lean Six Sigma Supports Joint Venture: Via ASSEMBLY: Crossroads in the UK ...

Perkins and Japanese manufacturer Ishikawajima Shibaura machinery, Ltd. (ISM) launched a joint venture company, Perkins Shibaura Engines, Ltd., and a manufacturing facility in 1996 adjacent to the Perkins manufacturing plant in Peterborough, UK. The original product was the Perkins 100 Series engine. ISM has been manufacturing agricultural equipment and engines since the 1940s and is one of Japan's leading suppliers of small engines and tractors. ISM is part of Ishikawajima Harima Industries - (IHI), one of Japan's largest industrial companies.

Perkins Engines is a wholly owned subsidiary of Caterpillar Inc. and the world's leading supplier of off-highway diesel and gas engines in the 4 - 2000 kW (5 - 2600 hp) market. Perkins' key strength is its ability to tailor engines precisely to meet customers' requirements. More than 300,000 engines are manufactured every year -- that's one every minute -- to 21,000 different specifications. For more than 75 years Caterpillar Inc. has been building the world's infrastructure and, in partnership with its worldwide dealer network, is driving positive and sustainable change in every continent. With 2002 sales and revenues of $20.15 billion, Caterpillar is a technology leader and the world's leading manufacturer of construction and mining equipment, diesel and natural gas engines and industrial gas turbines.

Operational Excellence: Six Sigma Work Process Change ...

IntraWest announces quarterly results and sees some increase in expenses as it ramps up its Six Sigma operational excellence program. ...

... "A new operational excellence initiative (modeled off Six Sigma) designed to change our work processes in order to derive cost savings and efficiencies in the future, which added $1.2 million of costs. " ...

Operational Excellence: Six Sigma Work Process Change: Via Intrawest: INTRAWEST REPORTS THIRD QUARTER FISCAL 2006 RESULTS ...

Lean Manufacturing ERP Selection Criteria ...

Lean manufacturing features, such as e-kanban, were part of the criteria of enterprise resource planning (ERP) system selection. SAP bests Oracle in this selection process. ...

... "Southco also wanted an ERP system that could support its lean manufacturing initiative with features like electronic kanban and inventory management. " ...

Lean Manufacturing ERP Selection Criteria: SAP Bests Oracle at High Profile Mid-Market Account: Via Managing Automation ...