Six Sigma analysis reduces solar panel thickness and increases revenue by $100K

A solar power company location in Shanghai, China discovered that their manufacturing process was producing unacceptable levels of variability in the thickness of their silicon nitride films. They needed to control the thickness of the film to improve the solar cells’ surface energy efficiency levels. Using statistical analysis, they were able to pinpoint and rectify […]

Lean for Hope Program Helps Global Social Sector

Lean for Hope is an initiative associated with Honsha (founded by Sammy Obara), which focuses on applying Lean principles to create positive social impact. Lean methodologies, originally developed for improving efficiency in manufacturing, are adapted to help organizations in the social sector enhance their operations, reduce waste, and better serve their communities, such as education, […]

Improvements to container shipments result in 80% reduction in time and $180K reduction in penalty fees

Food for the Poor, a nonprofit organization, transformed its manual container shipping process into an efficient digital workflow. Previously, the Gift-in-Kind (GIK) team relied on printed documents and informal communications, leading to frequent delays and errors. On average, 13 to 15 containers missed their shipping deadlines weekly, incurring over $180,000 annually in penalty fees. The […]

Book Review for “Government in Motion: Applying Lean Principles for a More Agile Government”

As process improvement consultants, we are used to dealing with profit margins, customer satisfaction, efficiency, yields and cycle times. But what happens when you step into the public sector, where success is measured in policy outcomes, equity, long term impact (years or decades into the future), transparency and compliance? Terra Vanzant Stern’s Government in Motion: […]

Brevard County saves 2000 hours and 50% rescheduling to inspection permits

Brevard County implemented Lean Six Sigma projects to improve its building permit inspection process, which consists of over 40 different inspection types and an average 200-300 inspections conducted daily. Two key projects were identified, and selected county employees were organized into teams to dissect and examine every part of the process. focused on online inspection requests […]

Boosting care quality using Lean Thinking

Shenzhen Hospital of Guangzhou University of Traditional Chinese Medicine committed to developing a Lean culture through training, project-based improvements, and a robust coaching system.  Shenzhen Hospital adopted the principle of “Quality is life, technology is bones, service is blood, culture is soul” to drive their pursuit of high-quality healthcare. They trained 56 Lean Green Belts – individuals […]