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
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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
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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

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6. Lead time reduction & cargo tracking
6. Lead time reduction & cargo tracking
Client Sector:
Transportation & Logistics
Summary Results:
  • Depot personnel had a better understanding of the relevant metrics
  • Proof of concept enabled implementation of software application
  • The Lean Ireland report was used by depot management to further promote the software application
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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
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8. Lean transformation at an automotive manufacturing site
8. Lean transformation at an automotive manufacturing site
Client Sector:
Manufacturing
Summary Results:
  • Manufacturing lead time fell from 13.5 days to 5.9 days
  • Manufacturing volumes increased by 73%
  • Plant inventory turns increased from 8 to 13 annually.
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