Employees can reach Six Sigma black belt level, Six Sigma green belt level and Six Sigma yellow belt level. Each level has a deeper understanding of the process and can help to implement the best practices. Most successful projects are led by Six Sigma black belt level. This case study will provide more insight into how Six Sigma can help businesses. Catalent Pharma Solutions is a leader in developing solutions for the pharmaceutical, veterinary, biological and consumer health industries. The company was faced with high numbers of defects after producing millions of units. The process flow was slow because of the time required to analyze the samples. Six Sigma processes were applied to address these issues. The company specifically required a solution for their proprietary product known as Zydis. The company needed new systems that would help to predict the process variation. The improvements are also supposed to help operators understand statistical analyses.

The project team devised a database to collect information. Control charts were also completed and entered automatically. The programming language used for automation was flexible and easy to replicate. The efficiency was improved by making these changes. After two weeks of implementing Six Sigma processes, the company prevented the loss of two batches of product, which was worth 50,000 pounds. This case study demonstrates how companies can improve processes to meet Six Sigma standards, prevent loses and save money. Companies that save money can reallocate the funds towards research and design or improvement of other processes. Every company should try six sigma processes.

Six Sigma Projects Can Be Improved Significantly

Consider enrolling your employees in Six Sigma GMA programs to help your employees design processes that increase productivity and save the company money. Every business should develop a sound strategy for improving business processes according to Six Sigma principles. These companies will significantly improve and offer customers quality product on a consistent basis.

Read More Six Sigma Case Studies:

Amazon Six Sigma Case Study

Case Study: Lean Six Sigma Improves Environment – Baxter Manufacturing

Case Study: Lean 6 Sigma in Aerospace Manufacturer Streamlines Processes & Improves Cycle Time

3M 6Sigma Case Study – Pollution Prevention

The post Demonstration of Six Sigma Principles through Catalent Pharma Solutions appeared first on 6sigma.

Baxter Manufacturing employed the use of Six Sigma business practices to improve its environmental footprint. With the implementation of Six Sigma principles, the company hoped to become more efficient. After applying Lean manufacturing principles, Baxter witnessed a decrease in waste generation. In fact, the company doubled its revenue and its size, but it maintained the same level of waste generation. Here is what the company did to achieve this goal. A cross-functional team led by a person who had completed Six Sigma training was formed to implement the plan developed. These people had earned their Six Sigma certification and were poised to deliver instructions according to Lean Six Sigma principles. Six Sigma black belt leaders, Six Sigma green belt leaders and Six Sigma yellow belt leaders help to achieve the goals of the organization.

Accurate data was instrumental to the process. The data was collected to measure water discharge. Flow meters, energy readers and stopwatches were essential to the process. Measurement devices can usually be provided at little or no cost. Experts may be needed to make assessments if the expertise is not available in-house. Lean consultants were brought into the company to help facilitate change. To decrease increasing energy costs and cost of water purification supplies, value stream maps were created to help the team implement the plan. Environmental metrics were incorporated to measure results and facilitate change.

Three future state maps were created for various stages of the change. Baxter’s plan was designed to save the company 170,000 gallons of water. The plan also saved $17,000 in three months without making a significant investment in new procedures or technology. The plan eliminated the need for expansion in the plant’s wastewater treatment plant. After the implementation, the team leaders were promoted to corporate positions because of their efforts.

SixSigma Improves Manufacturing Processes

Many companies have benefited from using Six Sigma to improve business practices. Many companies have proven how Six Sigma changes the way business is conducted. With improved processes, companies become more efficient, productive and profitable. With reduced waste, people can live in a cleaner and safer world.

Global Six Sigma offers both Live Virtual classes as well as Online Self-Paced training. Most option includes access to the same great Master Black Belt instructors that teach our World Class in-person sessions. Sign-up today!

Checkout Virtual Classroom Training Programs

Self-Paced Online Training Programs

Read More Six Sigma Case Studies:

Amazon Six Sigma Case Study

Demonstration of Six Sigma Principles through Catalent Pharma Solutions

Case Study: Lean 6 Sigma in Aerospace Manufacturer Streamlines Processes & Improves Cycle Time

3M 6Sigma Case Study – Pollution Prevention

The post Case Study: Lean Six Sigma Improves Environment – Baxter Manufacturing appeared first on 6sigma.

Case studies are an excellent way to learn more about the Six Sigma process. Review the case study to determine how the processes could help your company. Here is one example of a case study that may illuminate how the Six Sigma process works. A small company that manufactured parts for the aerospace industry wanted to reduce the costs of manufacturing. This company decided to use Six Sigma to improve processes and reduce the machining cycling time. This reduction process was designed to help decrease the manufacturing costs within organizations. Key project engineers within the organization obtained Lean 6 Sigma certification after Six Sigma training.

The Six Sigma black belt team members organized a team to help facilitate the process. The team included management and machine operators. A team of Six Sigma green belt and Six Sigma yellow belt members implemented the DMAIC process. During the “Define” phase, the cycle time was measured at 1200 seconds. The Lean Six Sigma team wanted to reduce this time by 50 percent. The sigma level was set at a minimum level of three. The team also found several risk factors. The risk factors included: overtime reduction, faster business pace and less time for inspection. A process map was completed to help team members understand the current state of the company’s process and also to implement a plan.

During the measure phase, key metrics were defined. Collected data was analyzed for stability during this phase. Statistical analysis was used, and the causes for long cycle times were identified. The data revealed areas of improvement. Up to 40 percent improvement could be made in some instances. During the improvement phase, solutions were devised and lean concepts were used to generate potential solutions. Several solutions were presented to management and ranked. The solutions were put into pilot stage.

When the process was measured, the process was proven stable and had a Sigma value in excess of five. The process steps were reduced by 20 percent. During the control phase, a new process map and training plans were developed and implemented. Potential problems were found in the environment, human factors and methods. To manage the risks, control plans were put into place. After implementing the Lean 6 Sigma principles, there was a 46 percent improvement in the cycle time, and there was an 80 percent reduction in variation.

Lean 6 Sigma Principles Improve Business Practice of Small Companies

Even this small company benefited from the principles of Lean 6 Sigma. From small to large, every company seeking to improve should try Six Sigma. 6 Sigma training is recommended. After the training, the team will be ready to implement a plan for improvement.

Global Six Sigma offers both Live Virtual classes as well as Online Self-Paced training. Most option includes access to the same great Master Black Belt instructors that teach our World Class in-person sessions. Sign-up today!

Checkout Virtual Classroom Training Programs

Self-Paced Online Training Programs

Read More Six Sigma Case Studies:

Amazon Six Sigma Case Study

Case Study: Lean Six Sigma Improves Environment – Baxter Manufacturing

Demonstration of Six Sigma Principles through Catalent Pharma Solutions

3M 6Sigma Case Study – Pollution Prevention

The post Case Study: Lean 6 Sigma in Aerospace Manufacturer Streamlines Processes & Improves Cycle Time appeared first on 6sigma.

The concept became popular after other companies recognized the benefits. Jack Welch and General Electric was one company that perpetuated the idea and made it popular. When profitability, productivity and efficiency improved, there were few arguments regarding the benefits of Six Sigma. Companies utilizing Six Sigma practices engaged in analysis and plan development to bring about change. Here is one example of how 6Sigma was successfully used in a business. 3M strives to prevent pollution in its organization by implementing Six Sigma best practices. With the help of Six Sigma, the company became a leader in corporate pollution prevention.

3M believes in preventing pollution through proactive measures and addressing the pollution at the source rather than being reactive and addressing the issue once it has already entered the environment. In 31 years, the company has prevented 2.6 million pounds of pollutants from entering the environment and also saved over $1 billion. To achieve Six Sigma standards, 3M enrolled over 55,000 employees in Six Sigma training. These 55,000 earned Six Sigma certification and Six Sigma black belt status, Six Sigma green belt status or Six Sigma yellow belt status. With the helped of trained professionals, over 45,000 Lean Six Sigma projects were completed. In 2007, the company trained two 6Sigma black belts and a master black belt. The black belts provided coaching to the organization. All of the team members were required to have at least a Lean Six Sigma green belt.

Two weeks of training was required to become a 6Sigma green belt. 3M’s Six Sigma projects focus on reducing waste, air emissions, greenhouse gas emissions and energy use. By 2006, over 70 percent of the 3P projects in the organization were operating according to 6Sigma methods. The results were favorable. The company used Six Sigma to reduce volatile air emissions. 3M’s goal was 25 percent reduction in volatile air emissions. The company achieved 61 percent reduction. 3M also strove to reduce the U.S. Environmental Protection Agency Toxic Release Inventory (TRI). The goal was 50 percent reduction, but the company achieved 64 percent reduction. Improving energy efficiency was also of importance to 3M.

A goal of 20 percent reduction was set, and 27 percent was achieved. In general, the company tried to double the number of Pollution Prevention Pays (3P) projects from 194 to 400. Instead, the company reached 1262 projects, which is more than double the goal.

Six Sigma Saves Money

3M proved that 6Sigma best practices can save companies money. If the processes are implemented appropriately, companies become more efficient, productive and profitable. Global Six Sigma offers both Live Virtual classes as well as Online Self-Paced training. Most option includes access to the same great Master Black Belt instructors that teach our World Class in-person sessions. Sign-up today!

Checkout Virtual Classroom Training Programs

Self-Paced Online Training Programs

Read More Six Sigma Case Studies:

Amazon Six Sigma Case Study

Case Study: Lean Six Sigma Improves Environment – Baxter Manufacturing

Case Study: Lean 6 Sigma in Aerospace Manufacturer Streamlines Processes & Improves Cycle Time

Demonstration of Six Sigma Principles through Catalent Pharma Solutions

The post 3M Six Sigma Case Study – Pollution Prevention – 6sigma appeared first on 6sigma.