Six Sigma

    
Multi-National Chemical Company, UK.
Designed and presented a series of statistical process control training workshops for the UK operations of a major multi-national speciality chemical manufacturer. Participants included production supervisors, QA/QC staff, process engineers and operators, who learned how to apply specially adapted CEDAC diagrams and process control charts using real time data to continuously improve process capabilities, CpK and move towards six sigma quality. By forming multi-disciplinary quality improvement teams to apply these SPC techniques to one particularly problematic chemical batch process, after six months "right first time" pass rates improved from 86% to 99%, reducing rework batches, lowering cycle times by 20% with significantly lower manufacturing costs (annual savings £78K).

European Electronic Component Manufacturer.
Ran a series of six sigma training workshops for blackbelts, who applied the knowledge to business processes with results being:- · Reduced defects in one manufacturing process from 2630 to 500 ppm. · Improved supplier performance from 0.71 to 2.33 CpK. · Reduced cycle time in supply chain from 35 to 19 days.

Major Multi-National Petrochemical Client.
Ran a series of Process Capability workshops and associated consultancy to assist the client move towards Six Sigma. This included sales force training to enable them to sell the increased product volumes due to improved process capability which was achieved as a result of the six sigma training. Over a period of two years the capability on a key customer satisfaction measure rose from a CpK of 0.3 to 2.4.

Cable Manufacturing Company.
Led and facilitated a series of Variation Reduction Events in a cable manufacturing company. In each five day event a team of 6 or 7 employees, including process operators and engineers, carried out experiments on a chosen production line to reduce waste, increase line speed or improve product quality. One event established the operating conditions that allowed a 90% increase in line speed.