Client Case Studies
Lean6Sigma has over 40+ clients in New Zealand in a wide range of sectors (Service, Logistics, Government, Manufacturing and Construction). The Auckland Council Accounting Shared Services business unit was a benchmark reference site for its use of lean visual controls in its Shared Services operations that have been developed with Lean6Sigma Ltd.
These are a sample of some of those sector case studies:
Case study – Industrial Fluid Connections
- Lean White, Yellow and Green Belt training 2016/7 in Auckland for 8+ staff
- Lean journey map audit completed
- Projects included
- Reducing backorders
- Improving Goods Inward efficiency
- Reduce product pick times
- Mobile operations optimisation
- Implementation of product mistake-proofing, process flow relayout and 5S workplace organisation at a regional facility.
Case study – Freight Forwarder Logistics
- Lean Yellow and Green Belt training 2015 in Auckland for 6 staff
- Targeted the Days to Execution an Invoice (DETI) lead time which was sitting at 8+ days
- Used a lean roadmap to streamline the process to 5.5 days
- An off-site workshop secured the engagement of key staff that ‘touch’ the process
- Bi-product was to speed up the quotation process by centralizing pricing group emails.
- Became improvement reference project within Logistics Group
Case study – Electronics continuous improvement programme
- Lean6Sigma has deployed a total CI programme for an electronics company
- Staff trained - 140 Yellow Belt, 62 Green Belt and 4 Black Belts trained 2013-2016.
- Over 70 projects closed – Operations, Back Office and Supply Chain
- Intranet project pipeline established
- 600 Staff each contribute 4 Opportunities for Improvement (OFI’s) per year
- CI programme sustained with existing now conducting own YB training for new entrants
- CI Operations best practise site
Case Study – Council Properties Dept
- Continuous Improvement started with senior team White Belt session for alignment
- Capability build with Yellow Belt (18 candidates) and Green Belt training (16 candidates)
- Status - 4 Green Belt projects completed including process improvements to
- Workspace request process
- Council building energy optimisation
- Actioning maintenance requests
- Fleet vehicle management system
- Renewal work process
- Introduced the use of leading vs lagging measures concept
Case Study – Govt Transport organisation
- 50+ Yellow Belts trained (two-day course) and certified following evidence of tool and roadmap usage
- Focus on Road Corridor Access and Customer Service
- Two GB courses run with 10 candidates
- Projects completed included
- System onboarding process
- Process approval process
- Temporary traffic monitoring
- Incorrect referrals
- Travelcard refunds
Case Study – Govt Transport Body
- Started with Yellow Belt two day course (22 candidates) and one 3 day GB course (7 candidates)
- Status – 2 GB projects completed including process improvements for
- Whole of life property tactics
- Project defects arising after handover from maintenance main contractor
- Whole of life project resulted in substantial savings with more to follow by increasing post project property value
Case Study - International Airport
- CI programme shaped by senior team – White Belt session
- Collaborative Group integrated training - with key agencies (Security, Customs, Bio Security)
- Two YB one day courses (20 candidates) and two 3 day GB courses (12 candidates) completed
- Status – 8 projects completed including process improvement to
- Improved passenger wayfinding
- Queue management at oversize bags
- Bus hop operations
- Concourse congestion
Case Study - Lean Construction
Partnered with Constructing Excellence
Lean programme overview
- To establish in-house problem-solving capability
- To apply to a range of back-office and site issues
- Using lean to improve process efficiency and last planner to provide collaborative programming
- To standardise and sustain improvements gained through lean process improvements
Partnered with Constructing Excellence.
Project examples (250+ projects)
- Travel card process
- Referral reduction
- Stock area organisation, Pull planning
- Establish waste card process
- Contaminated materials management
- Street Lighting contract
- Waste elimination at a construction site
- Cost saving for renovated home sales
Case study - Rapid Improvement Event (Kaizen)
Workshop approach used with the Plan Do Check Act roadmap. Aim is to accelerate process improvement project with a short series of workshops. Tools used include Problem statement/Objectives In/Out Scope, VOC, Fishbone, Generating Solutions and Standards. Example shown is a Council Rebates Process wallchart.
