Reducing Waste on Chicken Nugget Line – Part 2 of 2

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The following is Part Two of a two-part article. Part One follows the first two phases of a DMAIC (Define, Measure, Analyze, Improve, Control) project at Kahiki Foods. Part Two follows the completion of the project – the Analyze, Improve and Control phases. Analyze During the Analyze phase, the monitoring of the average amount of […]

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Reducing Waste on Chicken Nugget Line – Part 1 of 2

Published:

The following is Part One of a two-part article. Part One follows the first two phases of a DMAIC (Define, Measure, Analyze, Improve, Control) project at Kahiki Foods. Part Two follows the completion of the project – the Analyze, Improve and Control phases. Kahiki Foods, a family-run Asian foods manufacturer with about 200 employees in […]

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Gemba Walks Come to Life at Fairbanks Morse Engine

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Editor’s note: In a previous article, author Lindquist describes what a gemba walk is. Here he presents three examples of gemba walks. Gemba walks at Fairbanks Morse Engine demonstrate the importance of the sometimes-overlooked basics of process improvement. Case Study One Single Process – Pama Machining Center Observation: The objective of a series of events […]

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A Case of Mistaken Capability

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Lean Six Sigma (LSS) teams focus on the statistical analysis of metrics when identifying opportunities for improvement. The strong focus on data-driven evaluation, however, can overshadow the human element that exists behind the data collection plan. Despite its importance, the impact of human interaction is not easily visible or quantified, buried under reams of data. […]

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Reducing WIP at a Frozen Food Manufacturer – Part 2 of 2

Published:

The following is Part Two of a two-part article. Part One follows the first three steps of a DMAIC (Define, Measure, Analyze, Improve, Control) project at Kahiki Foods. Part Two follows the completion of the DMAIC project – the Improve and Control steps. Improve The enhanced choke-point analysis completed in Analyze verified the chicken processing […]

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Reducing WIP at a Frozen Food Manufacturer – Part 1 of 2

Published:

The following is Part One of a two-part article. Part One follows the first three steps of a DMAIC (Define, Measure, Analyze, Improve, Control) project at Kahiki Foods. Part Two follows the completion of the DMAIC project – the Improve and Control steps. Kahiki Foods is an expanding, family-run Asian foods manufacturer with about 200 […]

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DMADV Case Study: Performance Management System Redesign

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To facilitate the development of its employees and better respond to the changing business environment, one department of a large financial-services company decided to revamp its existing performance management system through a Six Sigma project. A pre-project analysis revealed that a complete redesign of the system was required. As incremental improvement in the existing system […]

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HMO Formulary Standardization Six Sigma Breakthrough

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Business Issue All medications are not created equally. Reopro (generic name: abciximab), Integrilin (generic name: eptifibatide) and Aggrastat (generic name: tirofiban) are all platelet-inhibiting drugs used in cardiac care. Each is priced differently. They act on patients in slightly different but clinically significant ways. The key critical to quality issue in healthcare is patient safety. […]

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Improving Staff Scheduling at Providence Health System

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As with most hospitals, labor is the largest budget expense at the Providence Alaska Medical Center (PAMC) in Anchorage. But benchmarking indicated that staff utilization at PAMC, a part of the Providence Health System, was above the 75th percentile of the national average. To remedy this, in October 2003, a multidisciplinary team (nursing, leadership, finance […]

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Improving Financial Services Through TQM: A Case Study

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The work described in this case study was undertaken in a young, rapidly expanding company in the financial services sector with no previous experience with total quality management (TQM). The quality project began with a two-day introductory awareness program covering concepts, cases, implementation strategies and imperatives of TQM. The program was conducted for the senior […]

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