Lean Six Sigma

In process industries, products are manufactured in equipment complexes (called “plant”) consisting of columns, storage tanks, heat exchangers, pumps, compressors, furnaces and other such units, all connected by pipes, instrumentation systems, and so forth. Because of this integration, it is more important to focus on maximizing the overall effectiveness of…

How does working patiently and persistently to eliminate the 16 Big Losses not only have the benefit of driving up OEEs, but also help greatly to drive down costs? If a plant has been working flat-out to meet demand, for example, with its operators doing overtime and holiday work, increasing…

The losses holding back the efficiency of a fabrication, assembly or packaging operation employing mainly non-process-type equipment will be different from those in an operation that employs mainly storage tanks, columns, heat exchangers and similar process plant. The two types of operation will therefore be discussed separately, beginning with the…

A tool to help understand the set of reasons why a project is necessary. List of “consequences if the problem is not fixed” and ‘benefits of making the change”. People are motivated by threats and opportunities; Identify the stakeholder group who needs to understand why the project is needed; Brainstorm…