Six Sigma Peak Efficiency

Dow Corning is recognized by the American Chemistry Council for its energy efficiency, which was accomplished using Six Sigma techniques. ...

... "Many distillation columns operate the same way year after year and not running at optimum conditions compounds energy losses. The Carrollton site implemented a Six Sigma project to bring a column up to peak efficiency, and then replicate the results on a similar process. " ...

Via Madison Courier: Dow Corning wins award

Six Sigma Fever Challenges GE

GE may be a victim of its past successes, as it becomes challenging for the current CEO, Immelt, to replicate the stellar performance of the GE of the past, with Jack Welch at the helm, which leveraged Six Sigma for consistent operating efficiencies coupled with growth gains. ...

... "The 40-plus price-to-earnings multiple came from a nutty euphoria generated by recurring Fortune covers, Six-Sigma fever, unnaturally consistent earnings and Welch’s need to publicly front the narrative. " ...

Via Portfolio: Jeff Immelt

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

Cintas Six Sigma Efficiency Program

Cintas President and Chief Operating Officer was instrumental in the company's operational efficiency efforts, using Six Sigma methodology. ...

... "That led Cintas into implementing Six Sigma, a process-improvement methodology to increase efficiency across the company and an effort Holloman led before being named vice president of global supply chain management. " ...

Via Cincinnati Enquirer: Exec in small club

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

India Six Sigma Strength Delivers Value

With the potential of a global slowdown increasing, Indian outsourcing firms can leverage their strengths in Six Sigma and cost-effective delivery to differentiate themselves in the marketplace. ...

... "Even in a three-decade-old industry, firms are adding value by reducing average handle times per call by 30% to 40% using Six Sigma standards of efficiency. " ...

Via Knowledge @ Wharton: How Will Indian IT and BPO Firms Cope with a Global Slowdown?

Textron CEO Sees Six Sigma Benefits

Textron CEO Lewis Campbell believes in Six Sigma as the route to becoming a premiere multi-industry company. ...

... "Even though Cessna has been producing planes for 89 years and jets since 1972, they recently took 17% of the labor hours out of their single-piston aircraft. That's a big number. " ...

Via USAToday: Textron CEO

Six Sigma Achievement in Process Efficiency is Awarded

ATMI is recognized for its use of Six Sigma to drive growth at the company in its product lifecycle. A number of Six Sigma projects have been deliver with operational efficiency benefits realized. The company was recognized at the Global Six Sigma Awards 2007. ...

... "We are very happy to have our innovative approach to Six Sigma deployment independently validated, as it is a key contributor to continued growth, said Doug Neugold, Chief Executive Officer. This award is based upon our documenting how the tools and methodologies were used to design, develop, and commercialize our RegenSi(tm), AutoClean(tm), and Newmix(r) process efficiency solutions, each of which has the potential to save our customers many millions of dollars by bringing yield, cost, and throughput improvements to their processes, said Tim Carlson, Chief Financial Officer. Since inception, we've completed over 80 internal projects generating more than $20 million of savings for ATMI. " ...

Via ATMI: Best Achievement in Six Sigma

The Six Sigma Police See Savings Potential

Six Sigma discipline often requires policing. In this situation, the police are using Six Sigma to do the policing ... for operational efficiencies in their processes. They see potential benefits in cycle time reduction for the booking process. ...

... "The Mesa Police Department is one of four agencies nationwide that are participating in a pilot program of Six Sigma in police departments, said Mesa police Sgt. Kathy Kirkham ... " ...

Via EastValleyTribune: Mesa police

Failure Analysis in Six Sigma Methods

Dyadem enables Maidstone to analyze its failure modes, eliminate root causes, improve quality, and operate efficiently.

... "Maidstone has saved hundreds of thousands of dollars through the use of Six Sigma methodology and Dyadem's FMEA Pro-7 Risk Management Software -- commonly used to improve quality in manufacturing but rarely seen in the consumer products sector. Maidstone produces more than 60 million donuts per week and wanted to ensure top quality while making sure its production operations were as efficient as possible. Dyadem has helped Maidstone significantly reduce costs while improving quality at its 400,000 square foot facility in Brantford, Ontario. " ...

Via Dyadem: Product Failure Analysis Software

Lean Supply Chain Sorted and Straightened

Lean is not easy - in manufacturing or other business processes. But, it's results are achievable with the right level of committment. It can translate beyond the factory to the supply chain, where elimination of waste can scale across many inefficient processes that need sorting and straightening. Read on for some good insights on thinking beyond the plant boundaries. ...

... "It is admittedly easier to think about sortation and straightening in the context of manufacturing and warehousing than in the supply chain, but when you extend their definitions to include the development of good processes and procedures, their relevance becomes clear. " ...

Via DC Velocity: Supply Chain

Navy Lean Six Sigma Lowers Backorders

Navy leader shares his perspective on the benefits of lean. ...

... "Asked about his support for Lean Six Sigma, Roesner said the practice of continuous process improvement has helped lower backorders at NAVICP to their lowest point ever because we took out the unnecessary work. " ...

Via Battle Creek Enquirer: Federal Presentation

Lear Lean Manufacturing Implementation Drives Operational Efficiency Gains

Lear Corporation's lean manufacturing processes have driven productivity and operational efficiency for the company. Lear's lean implementation concentrates on the work environment, quality, the layout, and the flow of materials. ...

... "Tony Coomer, the company's vice president of Advanced Manufacturing and Continuous Improvement-Seating Systems, said lean manufacturing techniques have been deployed throughout the company's global manufacturing network.

Lear employees are trained on LMS during a three-week workshop. The training is conducted at all Lear plants by a lean manufacturing leader and employees receive LMS certification upon successful understanding of LMS principles and validation of model line projects which deploy LMS.

Product design is another key element in Lear's Lean Manufacturing System. Product design teams rely on LMS principles to ensure products can be manufactured in a lean environment. Approximately two thirds of product costs are locked into the initial design of the product, Coomer noted, so any effort to reduce cost after the initial design stage can only influence the remaining one third of the product's overall cost. At one facility, for example, product design teams incorporating design for lean principles in a model year change realigned workstations, changed production flows and made other assembly line changes to boost productivity.

Plant layout also plays an important role in Lear's approach to lean manufacturing. Lear uses Value Stream Mapping (VSM) to understand work flow and identify waste. In addition, extended VSM allows Lear to eliminate waste from the entire value stream -- from supplier to customer. VSM encompasses items such as freight costs, inventory controls and production changes. " ...

Via Lear Corp: Lean Manufacturing System Hikes Productivity and Reduces Costs

Sybron Lean Manufacturing Builds on Danaher Business System

Sybron emphasizes operational efficiency through application of Danaher Business System, based on lean manufacturing principles. ...

... "Sybron has adopted principles known as Danaher Business Systems, which he called a playbook to make the company run as a more efficient team. It's centered on kaizen, a quality improvement process that grew out of the teaching of W. Edwards Deming. " ...

Via Orange County Business Journal: Sybron

Operational Efficiency Limits?

Will high-efficiency enterprises reach a point of diminishing returns when it comes to operational efficiency? ...

... "Logistics experts with a Six Sigma background may argue that point is never fully realizable, although a retailer (or any business) must know when to cut and run when the costs expended to save money cost more than the eventual money saved. " ...

Via BloggingStocks: Limits of Efficiency

It's a Lean Six Sigma Town

Fort Wayne Indiana citizen benefit from city services improved by Lean Six Sigma methods. ...

... "The mayor will discuss how using high performance partnerships with Lean Six Sigma can improve city services and save taxpayers millions of dollars. Lean Six Sigma has saved Fort Wayne over $10 million, they said. " ...

Via Fort Wayne Business Weekly: Lean Six Sigma Showcase

Lean Transition Leadership

Lydall leader passes the baton to his successor and acknowledges the company's operational efficiency accomplishments through Lean Six Sigma. ...

... "With this accomplished, we directed our attention to renewing our focus on innovation through new-product development and on marketing efforts. And, finally, we tackled reducing costs and improving quality through our Lean Six Sigma program. I'm pleased with the progress that management and all employees have made on these fronts. " ...

Via Lydall: APPOINTMENT OF DALE G. BARNHART (PDF)

Software Project Success With Six Sigma

Six Sigma process can be applied to software selections in order to enable project success. ...

... "A successful software selection project is no different. It involves identifying the known problems within an organization, collecting appropriate user facts or issues, and identifying the underlying root causes. In this case, the root cause would be the deficiencies within the current software package that are driving the organization's operational inefficiencies. " ...

Via Accounting Software: Software Selection using Six Sigma

Cummins Six Sigma Exemplary

Cummins is an exemplar in the application of Six Sigma to all business process and has integrated the methodology into its culture. ...

... "The diesel-engine maker estimates it has completed 2,500 Six Sigma projects since 2000, saving or avoiding more than $1.4 billion in costs. " ...

Via Indianapolis Star: Six Sigma Success Story

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

LeanSixSigma Persists Even On Earnings Dips

Louisiana-Pacific Corporation reports first quarter net loss and affirms commitment to operational efficiency through Lean Six Sigma. ...

... "Rick Frost, CEO: I do not see this market improving substantially for the rest of 2007, Frost continued. We will remain persistent in completing our strategic capital projects, working to increase market share with our most important customers, and implementing cost and process improvements through our Lean Six Sigma efforts. " ...

Via Louisiana-Pacific Corporation: First Quarter 2007 Results

Manufacturing Consolidation Optimize Lean Opportunities

Aerosonic Corporation will consolidate manufacturing functions at its Clearwater, Florida facility. The consolidation is a continuation of Aerosonic's actions to be more responsive to customers' needs and to increase operational efficiency. ...

... "Avionics Specialties manufactures angle of attack stall warning systems, integrated multifunction probes, which are integrated air data sensors, and other aircraft sensors and monitoring systems. The Company will execute the consolidation plan in a phased approach to maintain delivery schedules and product quality. David Baldini, Chairman, President and Chief Executive Officer, commented: We are restructuring the Company in a way that maximizes efficiencies and increases profitability. This consolidation allows us to focus on continuous improvements in our processes and optimize lean manufacturing opportunities to ensure the best use of our resources and gain a new level of efficiency that is required to remain competitive. " ...

Via Aerosonic: Aerosonic Announces Consolidation of Manufacturing Operations ...

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 ...

Lean Cell Concepts: Make-to-Order

Stollenwerk shoe manufacturing stays on-shore and uses lean concepts to better manage working capital and remains globally competitive through operational efficiency. ...

... "Thanks to the introduction of lean manufacturing and cell concepts, the company can make a pair in seven hours. Shoes are made to order, with the inventory of finished products kept very low. " ...

Via Milwaukee Journal Sentinel: Link

Lean Techniques: GE Transportation Rail Manufacturing Plants

Pennsylvania and businesses invest in the improvement of manufacturing in the state. GE specifically is investing in lean manufacturing techniques to accelerate customer services and increase operational efficiency. ...

... "GE Transportation Systems plans to implement lean manufacturing techniques at its rail plants in Erie and Grove City, Mercer County, a project that is expected to cost $12.8 million. By applying this new operational strategy, the company expects to lower costs and shorten lead times to deliver orders and products. GE Transportation Systems has already fulfilled its commitment to the commonwealth to create 120 new jobs, is also retaining 4,486 existing jobs in Erie and 915 additional jobs at other Pennsylvania locations. The Greater Erie Industrial Development Corporation (GEIDC) supported the company in its efforts to obtain the investment package from DCED that includes a $250,000 Opportunity Grant and $250,000 in Customized Job Training (CJT). GE Transportation Systems manufactures locomotives, off-highway vehicles and wind turbines." ...

Via PA Governor Ed Rendell: GOVERNOR RENDELL SAYS 3 MANUFACTURERS INVESTING $19 MILLION TO GROW NORTHWEST PA OPERATIONS, CREATE 385 NEW JOBS

Printing Machinery Lean Manufacturing

The Canterbury Press sees success in the print market through lean techniques that drive operational efficiency. The company also invests in new machinery and automation to enable it to compete effectively in the marketplace. ...

... "Canterbury was an early adopter of lean manufacturing practices to cut costs and speed production. The ROLAND 700 will help the company's employee-owners notch that advantage up further to make production even more efficient and timely. " ...

Via What They Think: Read

Pharma Cuts Costs with Six Sigma

Big pharma firms, such as Merck, are focusing on operational efficiency in their supply chains, reducing their manufacturing footprint and eliminating costs through Six Sigma improvement programs. This is becoming a common recipe for larger drug firms as their margins are being compressed. ...

... "A lot of companies are moving some elements of R&D to India and China to cut costs. Many are adopting new manufacturing systems like Six Sigma. " ...

Via Investor's Business Daily: Link

Product Quality: Six Sigma Focus

C&D uses Six Sigma to improve product quality and improve operational efficiency. ...

... "We believe that the transition of Motive manufacturing to modern low-cost facilities with the elimination of a significant fixed overhead burden, combined with other cost reduction initiatives and a strong focus on product quality through our Six Sigma program, significantly improves our cost structure to allow us to more effectively compete in this market. " ...

C&D Technologies Announces Third Quarter Financial Results ...

LeanSixSigma: Danaher Business System

Accenture partner discusses the transformation that is achieved through Lean Six Sigma implementation. Sustaining high performance that translates into ongoing profitability is the goal. And, lean manufacturing principles become the enterprise's diet. ...

... "At the level of daily management, kaizen events employ a diverse range of operational efficiency tools – including Six Sigma and value-mapping techniques – to eliminate such sources of waste as excess inventory, waiting time, overproduction and quality defects. " ...

Via The Manufacturer: Link

Logistics Six Sigma Savings: 3M Brazil

3M will outsource pallet management to CHEP, trasitioning from exchange pallets. Using the Six Sigma DMAIC process, 3M validates significant room for improvement in its pallet operation. It expects to realize benefits with potential cost reductions for transportation and storage. ...

... "To determine whether CHEP services were appropriate for the company's operations, 3M used Six Sigma processes, solicited feedback from wholesale and superstore retail customers and conducted a comprehensive reference call at the Brazilian facilities of a leading global consumer products company. During the review process, managers identified a chance to decrease loss of pallets and reduce the quantity of renewed equipment derived by costumer returns. " ...

Via CHEP: 3M Brazil Sees Cost Savings With CHEP Program

CHEP is the global leader in pallet and container pooling services serving many of the world's largest companies. The company has more than 7,700 employees and operates in 44 countries. Combining superior technology and an asset base of more than 280 million pallets and containers, CHEP offers its customers exceptional value, a platform that enables reduction in customer product damage, and an environmentally sustainable logistical solution. Supply chains served include consumer goods, produce, beverage, and the automotive industry. With global partners that include Procter & Gamble, SYSCO, Kellogg's, Kraft, Nestle, Ford and GM, CHEP is known for Handling the World's Most Important Products. Everyday.

3M Brazil uses a number of management methods in its operations, such as theory of constraints in its supply chain. ...

Via AGI-Goldratt Institute: TOC World 2000 Video Presentations: "3M Brazil successfully applies the Theory of Constraints to their Sales and Operational Plan (SOP) to define their ideal sales mix in terms of addressing the market, the impact on production, and to evaluate the impact on their bottom line. "

In addition to its efficiency focus, 3M Brazil focuses on sustainability in its manufacturing operations. Its skills in pollution prevention are showcased here. ...

3P Examples: "3P team from 3M Brazil's Itapetininga facility replaced the solvent-based paper treatment process the plant used to manufacture packaging, medical and masking tapes with a new, water-based process. As a result of this change, the facility reduced solvent emissions by over 45 tons per year. "

Kahiki Lean Operations Drives Fundamentals

Company focuses on the fundamentals of operational improvement to drive profitability and growth. ...

... "Alan Hoover, President and CEO commented: These results clearly demonstrate that we are starting to realize the operational improvements that we have undertaken over the past year, including moving to a new manufacturing facility and implementing lean manufacturing. We have a very clear focus on growing our business profitably through the right mix of customers and products. We remain committed to building positive earnings by executing on the fundamentals: operational improvements, cost savings, and profitable sales. " ...

Via Kahiki Foods: Kahiki Announces Second Quarter FY07 Results

Market Forces: Lean Manufacturing ...

The impact of economic forces at play in the market on enterprise profitability cannot be stabilized solely by an operational efficiency program, such as lean manufacturing. ...

... "So then this whole idea of lean manufacturing hasn't really stopped the market gyrations, right? Chia: Not for everyone. Broadcom will see a revenue drop in Q3. " ...

Via Electronic News: Read

Lean Black Belt Coaching: Steel Consolidation ...

Consolidation in the global steel industry drives lean principles and operational efficiency. ...

... "Under French chief executive Philippe Varin, Corus had brought in 250 black-belt coaches in lean manufacturing and earned a reputation as one of the most efficient steel-makers in the world, while Tata came with a reputation as arguably the world's lowest-cost producer. " ...

Via Sunday Herald: Read

SAP PlantFloor Integration: Supports SixSigma Efforts

GE Fanuc and SAP partner to integrate SAP ERP business system with the plant floor automation system. The systems integration supports visibility to manufacturing operations in order to drive operational efficiency and continuous improvement. ...

... "The combination of GE Fanuc's Production Management solutions with SAP's Production Execution services allows for the gathering, analyzing and transforming of real-time data into information to continuously improve a company's level of productivity and performance. The real-time visibility and intelligence facilitated by the combined solution translates into improved agility, quality and efficiency by tracking and executing production operations through a closed-loop information exchange with the SAP Business Suite.

The solutions will provide product genealogy information traced by raw material consumption and production performance data. Additionally, they will drive operational efficiency and quality as well as the ability to respond quickly to manufacturing events and trends. These flexible, capable production systems will also meet the needs of companies that typically manufacture many variants of their products and require exceptional agility." ...

Via GE Fanuc Automation: GE Fanuc Teams with SAP to Ease Enterprise Integration, Improve Quality and Drive Productivity ...

Continuous Improvement Projects: Lean Manufacturing Program ...

Lean continuous improvement projects at Bocenor improve its operational efficiency and overall outlook for future growth and profitability. ...

... "Bocenor's operating profitability improved despite lower sales, thanks to the operational and financial optimization strategy carried out in prior quarters, particularly the implementation of the Lean Manufacturing Program which considerably lowered the window and door manufacturing breakeven point, the Company’s focus on higher value-added products and less-costly-to-serve markets, the initial benefits of the recovery plan undertaken at the Ste-Marie