Lean six sigma at a material recovery facility: a case study

Purpose – The purpose of this paper is to discuss the lean six sigma implementation process and its quantified benefits for the recycling industry. Specifically, the goals of the project were to improve the processes and increase capacity for a government operated material recovery facility (MRF) in Toledo, Ohio, USA.Design/methodology/approach – The six sigma DMAIC methodology was utilized for this study. This included aligning and optimizing processes and the removal of process‐generated defects and errors.Findings – After comparison of the current and future states of the MRF, it is found that by reducing non‐value added activities, productivity was increased by 7.3 percent for paper bales, 12.8 percent for commingled bales and 1.6 percent for old corrugated container (OCC) bales. The project generated over $65,000 in annual savings for the facility.Research limitations/implications – The findings are limited due to the focused nature of the case study and further cost‐benefit analysis can be carried o...

[1]  Pete S. Pande,et al.  What Is Six Sigma , 2001 .

[2]  S H Park,et al.  SIX SIGMA FOR PRODUCTIVITY IMPROVEMENT: KOREAN BUSINESS CORPORATIONS , 2002 .

[3]  Kai Yang,et al.  Design for Six Sigma and value creation , 2005 .

[4]  R. G. Stone,et al.  Mechanical engineering department , 1976 .

[5]  Jiju Antony,et al.  An Application of Six Sigma to Reduce Waste , 2005 .

[6]  Andrew Lee‐Mortimer.  Six Sigma: a vital improvement approach when applied to the right problems, in the right environment , 2006 .

[7]  Becki Meadows,et al.  Managing six sigma : a practical guide to understanding, assessing, and implementing the strategy that yields bottom-line success , 2001 .

[8]  Stephen Blumenfeld,et al.  Six Sigma, quality management systems and the development of organisational learning capability: Evidence from four business process outsourcing organisations in India , 2012 .

[9]  Young Hoon Kwak,et al.  Benefits, obstacles, and future of six sigma approach , 2006 .

[10]  Ronald J. M. M. Does,et al.  Six Sigma in a Dutch Hospital: Does It Work in the Nursing Department? , 2004 .

[11]  Loukas Tsironis,et al.  Lean Six Sigma in a service context , 2012 .

[12]  R. McAdam,et al.  A multilevel case study critique of six sigma: statistical control or strategic change? , 2004 .

[13]  Elisabeth Goodman.  Information Analysis: A Lean and Six Sigma case study , 2012 .

[14]  Thomas Pyzdek,et al.  The Six Sigma Handbook , 2000 .

[15]  Jiju Antony,et al.  Lean six sigma in a call centre : a case study , 2010 .

[16]  Peter S. Pande,et al.  The Six Sigma Way: How GE, Motorola, and Other Top Companies are Honing Their Performance , 2000 .

[17]  James R. Evans,et al.  Successful implementation of Six Sigma: benchmarking General Electric Company , 2000 .

[18]  Peter S. Pande,et al.  The Six Sigma way , 2007 .