I was tasked with investigating a 30% loss of monthly production in a period of 6 months a particular calendar year, compromising a revenue loss of $200,000 compared to the same time period of that previous year. Using Lean Six Sigma, I created a SIPOC, Project Charter and Pareto Chart to identify the biggest issues that our team faced (lack of training).
We then used The 5 Whys and a Cause & Effect Diagram to learn that highly skilled workers were absent during that low production month and unskilled workers were absent during the high production month. We then used this data to streamline processes and eliminate Non-Value Added Activities and were able to increase monthly production by 50% within 3 months.
