Below are Lean Six Sigma success stories in the Electronics industry organized alphabetically. For success stories in other industries, please visit our Lean Six Sigma Success Stories page.
Ellen Pekilis, the general counsel of CSA Group, and her team of six employees faced a growing stack of new, complicated legal work. The management team of CSA Group was unwilling to add new legal staff members so Ellen helped lead the time to better ways of working. The team brought work inhouse, shifted skillsets, and used Lean Six Sigma to dissect and streamline workflows.
Reducing cycle time flow from 100 days to just four was only one of the challenges when Lean and Six Sigma was introduced at the Kodak GCG manufacturing plant in Leeds, UK.
|Safety||Lost Time Accidents||Record 2 years without an accident|
|Yield||% of good||7%|
|Utilisation||% available time||24%|
|Productivity||Square metres per man||85%|
|Inventory||Average annual inventory||33%|
|Headcount||Full time equivalents||15%|
PI—and Six Sigma in particular—brings an emphasis on process stability and the data collection and analysis to support it. The fate of capital-intensive BPM proposals could be enhanced by incorporating a Six Sigma level of analysis in identifying benefits—both process and financial. Once implemented, BPM could incorporate, in addition to one-dimensional problem alerts, business activity monitoring (BAM) data used to measure and report on process stability. This functionality would allow recognition of trends and corrective action to be taken in anticipation of problems. In addition, this data on process variation can be used to develop improvement targets on an ongoing basis.
General Electric’s internal, 45-person internal startup, Energy Storage Technologies, has developed a new molten salt battery with a high energy density, recharges quickly, is rugged, and has a longer life than comparable batteries. Called the Durathon, it stores as much energy as batteries twice its size and lasts 10x longer. Six Sigma manufacturing experts in conjunction with the development team helped to reduce defect rates; the first battery to a customer broke on shipment, proving the worth of Six Sigma methodologies.
LG Electronics India has 60 six sigma projects running in the areas of production, purchase and HR. Some of the achievements are: The communication cost control project slashed the phone bills for the land line from Rs 13 lakh per month to Rs 5.5 lakh per month.
Xerox Lean Six Sigma is a powerful business-improvement tool that can enhance the effectiveness of Xerox and of the services we provide to our customers. It leads to solutions that no one person could ever develop alone. And the return on investment can be huge. The Xerox Lean Six Sigma tools, processes and principles are built on earlier Leadership Through Quality and new quality efforts at Xerox. Since 2003, Xerox people have been using Xerox Lean Six Sigma tools and methods in both internal projects and projects for customers. These projects focus on reducing waste and increasing effectiveness in vital business processes to bring measurable improvements in results for customers and the company.