Integrated Lean Six Sigma Implementation at a Large Chocolate Co.

World’s large Food MNC; with a leading chocolate brand in India. Introduction of integrated Lean Six Sima ( IL6S) as a process excellence startegy and create a road map for 5 factories across India.

Customized training on Lean Six sigma at all the levels, involvement of operators in Daily work management, Focus on getting first time right. Rewards and recognition, More focus on 5 S , TPM and Kaizen systemization.

Client:

World’s large Food MNC; with a leading chocolate brand in India.

Challenge:

Introduction of integrated Lean Six Sima ( IL6S) as a process excellence startegy and create a road map for 5 factories across India.

Project:

Identify key themes and important improvement projects and mobilise resourcs and support for the whole initiative for long term.

Approach:

Lean Six sigma DMAIC approach for problem solving which includes Assessment of process and activity, GE OEE of critical lines , gap assessment, yields, prioritization according to criticality, mistake proofing of the overall manufacturing process.

Activities:

process mapping and capability analysis, introduction of DMAIC approach and Tollgate Reviews, processes, training and ongoing coaching.

Results and financial returns:

:: Improved GE / OEE from average 60% to 70 % for all the critical lines.
:: COPQ reduction $4 millions per annum.

What makes this a “Lean Six Sigma” project?

:: Improvement of GE / OEE
:: Involvement of Employees
:: Assessment of Sigma value of the lines and projects identification based on the same
:: Intensive use of process metrics and quantitative methods
:: Introduction of new review techniques to improve defect containment
:: Mistake Proofing the manufacturing process

The Lean Six sigma toolkit:

Vale Stream mapping, Process capability analysis and metrics, cause and effect analysis, Pareto analysis, hypothesis testing and regression analysis, design of experiments Statistical Process Control (SPC).

How did we engage people and drive change?

Customized training on Lean Six sigma at all the levels, involvement of operators in Daily work management, Focus on getting first time right. Rewards and recognition, More focus on 5 S , TPM and Kaizen systemization.

Gazelles added value:

Extensive experience in Manufacturing Process Improvement initiatives by providing customized solutions for Cultural and technical challenges.

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