Benefits

These two tables give examples of some High Impact Events and Projects led by the founder of Lean-6Sigma Services.  For more details of specific improvements please contact us.

Examples of High Impact Events

Location

Year

Benefits
Improve Supply & Logistics Planning

UK

2001

  • Changed department from Functional to Value Stream Aligned
  • Identified major cost savings opportunities
Value Stream Baseline

UK

2001 and 2004 Identified major cost savings opportunities
Maintenance Department Baseline

UK

2002

Identified major cost savings opportunities
Lean QA Laboratory

UK

2003

  • Applied Lean Laboratory Approach (see separate project) to improve productivity
  • Saving £100K p.a.
Eliminating Contamination in Monoclonal Anti-bodies

USA

2006

Reduced Shutdowns, saving $300,000 per shutdown
Shortening Process Changeover Times

USA

2006

$50,000 per day x 20 days = $1 million p.a.
Doubling Product Throughput

UK

2008

  • Applied standard work technique
  • Prevented stock-out, potentially saved £ millions
Finance Department Baseline

UK

2009

Identified activities to cut headcount by 25%


Examples of Projects

Location

Year

Benefits
Waste Reduction in Documentation

UK

2000

  • Reduced error rate
  • Reduced effort
Inventory Reduction

UK

2001

  • £3 million one-off inventory reduction
  • Measures to prevent recurrence
Maintenance Planning System

UK

2002

  • Improved service to customers
  • Saved £0.5 million p.a.
Eliminating Defects in Quality Control

UK

2003

  • £1.5 million one-off saving
  • Prevented stock-out and major expense
Process Telescoping

UK

2003-4

  • Eliminated a process manufacturing stage
  • Saved £150K p.a. and a one-off saving of £14 million
Lean QA Laboratories

UK

2004

  • Higher productivity
  • Shorter lead time
  • Saving £500K p.a.
“Manufacturing Execution System” (MES)

UK, Ireland & Singapore

2004-8

  • Manual Paper Manufacturing Records converted to automated Electronic records
  • Process and quality data analysed in real time
Transformational Change 1 – Improving New Product Introduction (NPI)

UK, Ireland & Singapore

2007

Programme to smooth NPI from Research & Development and accelerate product transfer

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Diagnosis and Solution Identification

Implementation