“Lean Sigma gives us a powerful new set of tools to quickly eliminate waste – and provides direction and quality improvement for processes we can’t easily see, touch or feel.”
Gregory L. Flint, Chief Financial Officer
Cold Spring Granite Company
“Speed is the name of the game. Our Lean Sigma transformation has intensely motivated our people and created an understanding of real teamwork. In less than a year, we have generated 4X ROI from increased throughput and yield improvement.”
Felix Viveros Melo, Brewery Director
Cerveceria Cuauhtemoc Moctezuma – Monterrey
“We’re using Lean Sigma to improve all our processes, which allows us to build stronger customer relationships, launch numerous new products and achieve major reductions in production costs.”
T.J. Johnson, Vice President of Corporate Development and Operations
Ventana Medical Systems
“We needed to improve much faster. Lean Sigma gave us the roadmap for rapid improvement and the enthusiasm to jumpstart our efforts.”
Dave Conrow, Group Vice President
Tennalum Division, Kaiser Aluminum
“Speed and flexibility are huge competitive advantages. We’ve made big reductions in changeover times, so we can make more SKUs every day – and deliver faster to our customers.”
Major International Tire Manufacturer
“We have been amazed at the benefits. We’re taking unbelievable amounts of time and effort out of payroll, order entry and inventory tracking.”
Paul Mechler, President
“We are honored to have been selected as the 2011 recipient of the Perfect Engine Award. The commitment to making all of our operations lean enterprises has transformed Carlisle and made us a stronger company. Efficiencies have improved at every level of our company and enabled us to increase our overall profitability in spite of difficult economic times. Our employees in every one of our operations not only enthusiastically welcomed the idea of making our manufacturing operations more productive, but became completely engaged in making it happen while taking pride in the contribution they each played. I believe our commitment to lean principles will continue to drive significant value creation throughout Carlisle in the years ahead.”
David A. Roberts, President, CEO and Chairman
Example in Action: A Crisis Avoided through Using the LeanSigma Methodology
One of our clients supplies packaging systems for dispensing food products. In one year, a large, brand-name customer received 30 complaints regarding leaking boxes. Even though that represented a miniscule percentage of the 30 million systems shipped, and a quality level far in excess of Six Sigma, the customer wanted our client to correct the problem quickly to avoid negative reviews on social media sites. Historically, above-Six Sigma quality in manufacturing is expected only in products where the safety of the consumer is at risk. However, the rise in widespread social media commentary is putting pressure on manufacturers in consumer products supply chains to seek higher levels of quality to protect their brand reputations.
The team used a Sigma Kaizen process (combination of Lean Kaizen and Six Sigma analytics) to identify the root cause of the defect. Each plant conducted Design of Experiments testing to determine optimal machine settings to produce an injected-molding part within a narrow band of tolerable acceptances.
What was likely to be a cumbersome project with a large scale investment of time and resources was actually resolved in a matter of months. We worked with the client to stop the leaking valves and delivered results as follows:
- Restored customer confidence through communication about the project and ensuing results.
- Committed to the same process for future problem solving for the client’s customer.
- Each plant can now use their own tooling and equipment to produce a part within a very close tolerance band and avoid leaky valves.
- The client restored confidence with its large customer and is now able to proactively focus on growth-oriented activities instead of a recurring challenge that would disappoint both consumers and their biggest customer.
TBM can also train your staff of continuous improvement professionals by providing LeanSigma Green Belt and LeanSigma Black Belt certification to groups of eight or more at your facilities or at a centralized training location in our Durham, NC office. Our training approach provides hands-on, experiential learning opportunities for your LeanSigma practitioners on site, at your facilities, addressing a real-world problem that exists in your company.
“How many consulting firms unconditionally guarantee every aspect of their work? TBM is the only one I know of.”
Former CEO and Chairman of the Board