Lean Six Sigma case study

Pharmaceutical manufacturing

Results from 28 manufactured batches after improvements: Out of specification (OOS) batches reduced from from 18% to 1%; standard deviation of active levels reduced by 59%, and Cpk improved from 0.35 to 1.17.

Air handling

Health and Safety risks associated with greasing air handling units was significantly reduced, the greasing process was improved, and time to grease reduced significantly. Bearing lifecycle was extended and risk of AHU failure reduced.

Pharmaceutical manufacturing

The time to sample raw material reduced by 45%, and the process resource requirement reduced from 4 to 3 people. In addition the error rate reduced by 91%.

Food processing

Pork meat processing

Slicer room yieled increased from 1,000kg to 1,500 Kg per head per week

Transportation & Logistics

Airlines & aviation services

Proof of concept and evidence based decision making to enable implementation of a new cargo handling software application

Financial Services

Banking (retail, commercial, investment)

100% compliance to regulatory deadlines achieved.