services > lean/six sigma and EHS performance improvement

STC helps clients develop and align policies, objectives, procedures, and metrics often enabling breakthrough improvements in performance. STC's services allow clients to accelerate technology transfer, ensure smooth corporate integration, and reduce risk. Our benchmarking studies identify best management practices that clients can adopt to implement their own EHS strategic vision. STC is a leader in helping clients apply Lean/Six Sigma techniques to improve EHS performance, often building bridges and improving relations between EHS and production personnel in the process. Our Black Belt and Green Belt qualified personnel are trained in the application of Lean tools which focus on increasing speed and efficiency to reduce costs and Six Sigma techniques that focus on improving quality and reducing costs. We work with client teams through the DMAIC (Define- Measure- Analyze- Improve- and Control) process to improve manufacturing efficiency, reduce costs and risks, and reduce EHS "defects" such as lost-time injuries, regulatory compliance problems, or management system non-conformances. In one application of Lean/Six Sigma methodologies, STC helped a client solve problems associated with storage of incompatible materials in laboratories. By examining the manner in which personnel used materials, the size and locations of containers, STC helped design a solution that reduced risk, simplified operations, and reduced insurance costs while also assuring compliance with the fire code. Applying Lean/Six Sigma methods to EHS issues in production operations have led to reduced costs and regulatory burden. STC has helped several clients improve their operations while also substantially reducing their chemical inventories. In addition to the direct cost savings of a smaller inventory, one client avoided the need to construct a new high hazard occupancy warehouse, eliminating the need to negotiate a new permit with the fire marshal, and saved the cost of design, construction, and operation of an additional building. By reducing inventory and "right-sizing" storage containers, other clients have seen reduced amounts of hazardous waste generation and dropped below thresholds for hazardous material inventory reporting. Other examples where STC has applied Lean/Six Sigma techniques that led to EHS performance improvement successes include: STC helped a client examine its behavior-based safety data with Lean/Six Sigma statistical and analytical techniques leading to improved safety performance. Implementation of 5S (a Japanese concept of housekeeping: sort, straighten, shine, standardize, and sustain) and rapid machine setup processes enabled Baxter International to reduce injuries, increase machine availability and significantly decrease scrap rates. PCB treatment process variability was substantially reduced at Onyx International by identifying key points and analyzing process capability. Applying process mapping helped Basic American Foods achieve scrap reduction objectives. A major west coast port reduced its time spent on its injury and illness inspection process by 75% and improved the effectiveness of the inspection process by more than 90% through measurement system analysis and application of multiple improvement techniques. "STC focuses time where it's needed to identify opportunities for risk reduction." - Medical Products Manufacturer

LSS Case Study- Chemical Management (83kb) LSS Case Study- The Case of the High pH (241kb) Statement of Qualifications (216kb)   Barb Ruble Randy Roig