Case Study: Lean Six Sigma Improves Order Quality at Ingersoll Rand Security Technologies
IR took on the task of improving the order entry process, utilizing the DMAIC approach and Six Sigma tools. As a result of these efforts, defects were reduced dramatically. The process itself is approaching a 70-percent reduction in defects, moving from 0.5 sigma to 3.53 sigma. Customer satisfaction has also improved tremendously.
Improve Pricing Quality with Six Sigma Methods
This article describes a situation faced by a real company–we’ll call it Acme Industries Inc.–in which it was compelled to adapt its Six Sigma manufacturing expertise to improve its pricing processes. The initial goal of generating $500,000 in incremental revenues during the first year was handily exceeded in only three months. More important, a subsequent across-the-board list-price increase was fully reflected in the top line for this product. By contrast, other product lines realized less than half the increase. That list-price increase, together with the tighter controls the Six Sigma team developed and implemented, resulted in $5.8 million in incremental sales in just the first six months following the project’s implementation, all going straight to the bottom line.
Aluminum Trailer Company
Aluminum Trailer Company Merges Lean and Green Principles
Aluminum Trailer Company (ATC) president Steve Brenneman discusses how the recession spurred his company to use Lean techniques in 2009 battle a drop in sales. Through a combination of streamlined material, information and part flows, the establishment of standards, and the communication of said standards through his company, Brenneman was able to cut warehouse space in half while slashing the sales cycle from 7 to 3 weeks. In 2010, Brenneman shifted the focus to greening his company by using Deming’s PDCA (Plan, Do Check, Act) methodology to upgrade to more efficient lights, encourage plastic, wood, wire, and cardboard recycling for line staff, and cut paper use 50% in the office.
Louisiana-Pacific Corp Earnings Call Yields Surprises
Curtis M. Stevens, CEO of Louisiana-Pacific Corp, mentions how Lean Six Sigma assists his company in being more efficient and effective at its manufacturing facilities, which produce building materials, industrial wood products and pulp.
Plasticard-Locktech International (PLI)
Plasticard-Locktech International (PLI) Invests $4.6 Million, Utilizes Six Sigma For Quality Control
Plasticard-Locktech International (PLI) will be investing $4.6 million in facilities and equipment. This includes 30,000 square feet of production space and 42 new jobs, thanks in part to the adoption of Six Sigma for quality control. Six Sigma has helped PLI develop a system of checks to ensure high quality products and satisfied customers.
General Cable Drives Down Costs Annually Thanks To Lean Six Sigma
Adopting lean and six sigma over a decade ago has allowed General Cable to remain competitive in an extremely price-sensitive and cyclical industry. The company has 6 master black belts, 64 black belts, 211 green belts, 290 lean technicians that enable them to have a consistency of response — in other words, everyone has both the tools and knowledge to handle situations. As a result of this continuous improvement mindset, General Cable is expected to drive down costs by several percentage points annually.
Cummins’ Legal Team Honored For Diversity
The Minority Corporate Counsel Association (MCCA) has named Cummins, Inc. the 2014 Employer of Choice for the Midwest Region. This award honors departments that demonstrate diversity and commitment to creating an inclusive workplace. Diversity is one of Cummins’ core values and their general council department has made tremendous strides in building diversity though Six Sigma.
NRAs 2014: Corporate Recycler of the Year
Cummins, a fortune 500 corporation that designs and manufactures power generation equipment and systems has been named the 2014 Corporate Recycler of the Year. Cummins has a goal of 95% recycling of its waste by 2020 across their 22 facilities and staff of 46,000. By using Six Sigma and Lean manufacturing techniques, Cummins’ sites increased their recycling rate to 97.87% this year!
The Jubach Company
Lean Six Sigma Improves Log Home Construction
Tim Jubach and his family are developers of log homes and land in Hocking Hills since 2002. They custom design through construction and after sale support. In 2003, Tim’s son joined the team and brought Six Sigma innovation to the company. His business experience not only complemented his father’s experience but also brought improvements to reduce waste. The company only has 5 employees and reported $2 million in revenue last year!
GKN Sinter Metals
GKN Sinter Metals Adds Kata to a Lean Journey in Germantown
In 2008, the profit return on sales was below zero for GKN Sinter Metal’s Germantown. The negative numbers started a fire in their shoes and although the fire was slow to start, the momentum began picking up in 2011 and 2012. With the momentum came the lean and kata concept. This was the missing piece at the Germantown facility.
3M and Rush Enterprises to Bring Quality Solutions to CNG Industry
3M and Rush Enterprises are getting ready to purse new design and manufacturing for compressed natural gas (CNG) systems to North America. The tanks to be supplied by 3M will be 30% lighter with 10% more storage than alternate types available. By pairing leading materials, technology, and expertise in Lean Six Sigma, the overall quality and reliability will be brought to a whole new level for customers.