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Lean and Mean Process Improvement |
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Lean and Mean Process Improvement is a straight forward presentation of the tools of process improvement. It touches on market analysis, team building, easy to use graphical tools and easy to understand explanations of statistical tools. This approach is not by accident. Process improvement has too long been focused on corporate wide roll-outs and “quality programs”. That approach to improving business performance is based more upon words than deeds, more upon supervision than leadership. Lean and Mean Process Improvement is written to be used by people at the cubicle and office level. This bottom-up approach will help senior management to understand processes “out on the floor” and how they impact the customer chain all the way to the end user. |
Book Summary
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Some 6 Sigma Topics Covered · Definition of Process Improvement · Market Segmenting · Finding the Voice of the Customer · Project Selection Guide · Easy Sampling Plan Tools · Easy to Understand Statistics · Team Selection and Building · Design of Experiment DOE |
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330 Pages of Six Sigma resource Material Price: $18.99 |
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To contact me: |
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Email: walt.m@searchparts.com Phone: 904-307-3286 800-486-0922 Ext 8871 |
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Helping Transform Businesses and Organizations with Lean Six Sigma |
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I have been involved in process improvement for more than 20 years. My experience gives me a unique perspective on how to import process improvement into an organization’s culture in a way that will stick. This book and associated materials are designed to help the individual improve their margin at the office, cubicle, and departmental level. As we all know, these are the locations where the rubber meets the road. No matter what process improvement or quality improvement program you are working in, we can help you rise above the crowd : Six Sigma Lean Six sigma Lean Enterprise Design for Six Sigma Total Quality Improvement Continuous improvement Etc. Good luck and have fun. Walt McIntyre Education Greenville College, Greenville, Illinois: 1975-1979. Graduated with a BA degree in Chemistry. Muskingum College, New Concord, Ohio: 1981. Took a course in geology to aid me in coal mine inspections. University of South Florida, Tampa, Florida: 1992-1995. Graduated with a Master of Science degree in Engineering Management. 3.95 GPA. Specialized Training Instrumentation & Control/Lab Apprenticeship Program, Columbus & Southern Electric, Conesville Generating Station: 1979-1981, Promoted to first line supervision before completing the program. Whitmire Leadership Training: 1981. Required training in the American Electric Power system for new managers. Tom Matone Managers Training 1989. Required management training at SJRPP. Magraw-Hill Supervisors Training 1991. Required supervisors training at SJRPP. MARC Training: 1992. Dealing with Bargaining Units. Required supervisor training at SJRPP. Preventative Maintenance Training by the American Management Association, Borden M. Coulter: 1992. Training on the various methods of maintaining equipment to achieve the best reliability and cost effectiveness. Dr. Phau Public Speaking Course: 1991. Training on successful public speaking. Certification in High School Coaching in the state of Florida: 1992. Project Management Training: 2000 Designing for Manufacturability: Motorola University (6 Sigma Component)- Completed 1999 6 Sigma Champion Training: Six Sigma Qualtec (6 Sigma )- Completed 1999 Basic Tools & Techniques Training: Six Sigma Qualtec (6 Sigma)- Completed 2000 Process Mapping & Control Charts Training: Six Sigma Qualtec (6 Sigma)- Completed 2000 Lean Enterprise: Six Sigma Qualtec- Completed September 2000 Green Belt Training: Six Sigma Qualtec (6 Sigma)- Completed September 2000 Black Belt Training: Six Sigma Qualtec (6 Sigma)- Completed and Certified June 2001 Master Trainer Certification: The Home Depot-Completed November 2002 Consulting Lean Six Sigma Associates: Developed Black Belt training modules on hypothesis testing. Home Depot Six Sigma Institute: Master Trainer: Responsible for development, review, and teaching of training programs for Six Sigma Champions, Black Belts, Green Belts, Orange Belts, Six Sigma Orientation, and Six Sigma Awareness. This work is connected with the initial roll out of Home Depot’s Six Sigma initiative. Also working on Store Safety Improvement Program St Johns River Power Park: Six Sigma Lead Team member. This team worked to find a consultant to help implement 6-Sigma within the JEA (Jacksonville Electric Authority). This included consultant selection, Readiness Assessment, training material development, policy deployment, Black Belt/Green Belt candidate selection, and project selection. Mentored 4 Green Belts and 1 Black Belt. Alternate Corporate Strategy Team member. Value chain analysis (coal supply through fly ash sales), facilitated specifications for fuel cost analysis and fly ash value as affected by fuel composition, establishing flow across functional divisions of the plant, applying Lean principles in shop areas, coaching 5-S, and evaluation and redesign of plant communications processes. 6-Sigma Projects Completed Petcoke Utilization at SJRPP: This project discovered the root causes for not fully utilizing petcoke (a cheaper fuel) and implemented corrective actions. The first year fuel cost savings was $2,100,000, as calculated by Fuels Management. Igniter Oil Consumption at SJRPP: This project outlined the causes for excessive light oil consumption and implemented corrective action. The first year savings was $750,000, as calculated by Fuels Management. This team moved on to address reliability issues. Reduction of Variation in Petcoke Concentration of SJRPP’s Fuel: This project uncovered the root causes of variation in the percent petcoke concentration in the fuel fed to SJRPP’s units and implemented corrective action. The standard deviation of petcoke concentration was dropped from 2.8 to 1.3 (confidence interval from 0.71% to 0.37%). This drop in variation allows SJRPP to increase their petcoke feed by 0.5 %. The first year fuel cost savings was $350,000 per year. Boiler Tube Failure Reduction: This project’s objective was to reduce the number of boiler tube leaks at SJRPP. The project focus was on the history of tube leaks and corrective actions at SJRPP. From this information a plan was formulated to head off future leaks. The results of implementing the recommendations from this project team were under evaluation in 2002. Leaks were reduced from an average of 5 per year to just 1 in 2002. The estimated savings was $800,000 in that year. Late Bill Payment Reduction: This project was focused on reducing the number of late bill payments by customers. Moving the payment due date from the 21st of the month to the 1st of the month reduced the late payment population by 25%. The cost savings realized by the completion of this project was under evaluation during 2002. Reduction of Moisture in By-Product Gypsum: This project was focused on the reduction in moisture, and consequent increase in selling price, of our by-product gypsum. The resulting increase in the selling price of the by-product gypsum is estimated to bring in $150,000 more per year. Evaluation of this cost data was underway in 2002. Time Sheet Error Reduction: This project was focused on the reduction of time sheet errors by employees. A narrowing of the project focus shifted the project to exempt employees only. The project was eventually given to the internal IT group for the development of an intranet time entry process. This was rolled out in 2001 and is still being evaluated. There are no cost savings data available. Bulk Materials Process Mapping: This project involved the mapping of all Bulk Materials processes. The project included all operations and maintenance. Though this was not a Black Belt project, several safety and cost reduction issues were addressed. This was a multi-team effort where I acted as a facilitator. Books Written Lean and Mean Process Improvement Papers Presented ORTEC International Conference on By-Product Gypsum: Toronto, Ontario, Canada. Presented a paper on SJRPP’s efforts at producing and selling by-product gypsum. FDGS Users Conference: Jacksonville, Florida. Presented a paper on SJRPP’s Flue Gas Desulfurization System. |
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About the Author |