Error proofing Lean Six Sigma case study

- Customer satisfaction
- Teamwork
- Streamlined processes
- Reduced costs
1. Pharmaceutical manufacture: OOS and the value of a gemba walk
1. Pharmaceutical manufacture: OOS and the value of a gemba walk
Client Sector:
Life Sciences manufacturing
Summary Results:
  • Cpk improved dramatically from the generic 0.35, to 1.16 and 1.17
  • The reject rate fell from 18% to 1%
  • The cost savings on the reduction in investigations was considerable
  • The client’s reputation was restored in the market
Read Full case study Get In Touch
2. Building management: air handling maintenance
2. Building management: air handling maintenance
Client Sector:
Building management
Summary Results:
  • All significant H&S risk was removed
  • Greasing time was reduced from an average of 51 minutes per event, to zero minutes
  • The project provided significant time/cost savings for the organisation
Read Full case study Get In Touch
4. Raw material sampling: pharmaceutical manufacture
4. Raw material sampling: pharmaceutical manufacture
Client Sector:
Life Sciences manufacturing
Summary Results:
  • The revised process flow had 18% fewer steps
  • The error rate reduced by 91%
  • The average sampling time reduced by 45%
  • The resources required reduced from 3 to 4 people to 2 to 3 people, depending on the sampling procedure

Read Full case study Get In Touch
7. Organisation structure and on-time delivery
7. Organisation structure and on-time delivery
Client Sector:
Financial Services
Summary Results:
  • A visual service progress tracker was put in place
  • Performance guidelines were established
  • Department restructured towards a more customer friendly cellular structure
  • 100% compliance with regulatory deadlines was achieved
  • Credibility of the department in meeting deadlines was restored
  • The organisation avoided potential costly penalties
Read Full case study Get In Touch
9. Digitization/ error proofing end-of-month reconciliation in finance
9. Digitization/ error proofing end-of-month reconciliation in finance
Client Sector:
Financial Services
Summary Results:
  • Month end reconciliation time reduced from 60 hours to 25 hours
  • €40K annual labour hours saved
Read Full case study Get In Touch