International specialty chemicals manufacturer wanted specialist help to improve pigment quality. Full scale CI deployment followed
Paloma Consulting worked with a global leading company for specialty chemicals. The £6 billion company has operational facilities in more than 200 locations worldwide and employs around 18,000 staff.
The client wanted to run a bespoke one off Lean Six Sigma Project to improve the manufacturing process for a pigment product. They had been unable to produce to the required colouristic characteristics that had been agreed with their customers in terms of specific measureable CTQ’s.
Paloma provided a dedicated Lean Six Sigma MBB for a 20 day continuous period working at the plant in Frankfurt. The MBB was provided with a local team of PhD qualified chemists and production staff and they set to work understanding the process. The standard LSS DMAIC problem solving process was used to achieve this. Value Stream and detailed process maps complete with Failure Modes Effects Analysis were developed. A mass of data was mined and some astounding knowledge was gained. Through thorough data analysis and process understanding, the root cause/s were established and process re-design took place.
Production was very quickly able to re-start and deliveries to customers resumed. Over £3million of previously unusable, quarantined intermediates were subsequently reassessed, validated as usable and released back into the supply chain. £1.1million in bottom line savings were realised. Management were so impressed they embarked on a 2 year LSS full deployment.
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