Successful Lean Six Sigma application case studies and benefits (Part 1)

Companies may have trouble implementing Lean Six Sigma practices, but if implemented successfully, this tool can bring long-term benefits and customer satisfaction, as well as change the workplace culture and work efficiency improvement.

The Lean Six Sigma method originates from process improvement systems such as Total Quality Management (TQM) and always evolves over time. Motorola’s Bill Smith coined the term Six Sigma in the early 1980s, rooted in a statistical measure. Its main goal is to continuously produce no more than 3.4 defects per million products (DPMO).

Initially, Six Sigma was used exclusively in component manufacturing, but over time, companies like 3M and GE began to use it in other areas as well. In the 2000s, companies began to combine Six Sigma’s quality improvement methods with lean manufacturing waste reduction methods, creating Lean Six Sigma. As manufacturing defects and waste decreased, the advantages of this method were gradually shown. The success of the strategy spread so quickly that in 2009, 82% of Fortune 100 businesses chose to apply Lean Six Sigma to their businesses.

As one of the successful businesses in adopting Lean Six Sigma, Allied Machine recognizes the importance of educating operators to shape a culture of continuous improvement and maintain good implementation of Lean Six Sigma.

The company’s executive vice president, Steve Stokey, took the initiative to apply for Lean Six Sigma training with employees to be able to lead the change of working culture at Allied. “The most important thing I have done is keep the organization moving forward and ensure the commitment of the management. By learning nomenclature, terminology, understanding the applications of Lean Six Sigma with which I always feel close to my employees, ”Steve shared.

During the training, instructors guide candidates in Lean Six Sigma advanced, covering DMAIC (identification, measurement, analysis, improvement, control), nomenclature, software. analytics, data-based techniques for process improvement and more. Participants learn and practice higher level procedures during the last week of class instruction.

Students submit their projects to a certified coach for review and, if approved, they will receive a black belt certificate. Not all participants achieve this status. Black Belt Training not only identifies potential leaders in our workforce, but also identifies areas that need improvement, even among current leaders, too. likes Ross Randazzo, excellent CEO at Allied Machine. Along with processes and products, training also provides continual improvement opportunities for an organization’s workforce.

Productivity and Quality Office