Industry: Manufacturing
Department: Production
Company: Orbis Bardstown
Financial Benefits Achieved: $54,916
Project Duration: 5 months
Project Type: Green Belt Project
Green Belt Project Success: How Lean Six Sigma Reduced Defects and Improved Quality
The Problem: Reducing Defects in Product IDs
When customers receive products with incorrect IDs, the consequences go beyond inconvenience—they can lead to lost trust, inefficiencies, and rising costs. At Orbis Bardstown, incorrect product IDs were the top customer complaint. Using a Lean Six Sigma approach, the company set out to solve this issue once and for all through a structured Green Belt project aimed at defect reduction.
The numbers told a clear story. Out of 2,095 pieces shipped, 12 resulted in customer complaints—a defect rate of 16.706 parts per million (PPM), equivalent to a sigma level of 3.625. The goal was ambitious: eliminate all complaints and reach a defect rate of 0 PPM.
Lean Six Sigma Tools in Action: Root Cause Analysis
To tackle the problem, a cross-functional team was created, including experts in manufacturing, production, quality, materials, and engineering. This diverse group ensured every angle of the process was covered.
One of the most effective tools used was the fishbone diagram, a hallmark of Lean Six Sigma. This brainstorming tool helped the team identify all potential root causes of incorrect IDs. After careful analysis, the main issue became clear: unrestricted access to the ID cage where labels were stored. Employees could easily retrieve the wrong IDs by accident, causing errors that cascaded through the supply chain.
Implementing Change: A Practical Solution for Defect Reduction
The team proposed a simple yet highly effective countermeasure. They introduced a lockable cabinet for ID storage, limiting access to authorized personnel only. By controlling this process step, the risk of human error was significantly reduced.
This solution, approved by the plant and regional managers, was easy to implement and aligned with Lean Six Sigma’s focus on practical and sustainable improvements.
Challenges Faced: Keeping Teams Engaged
The project was not without its hurdles. Initial skepticism from some team members led to lower motivation scores, averaging 3.5 out of 5 at the start. However, as the project progressed and results became apparent, motivation soared to a perfect 5.
Scheduling team meetings was another challenge. With representatives from multiple departments, finding suitable times required flexibility and persistence. Overcoming these logistical obstacles ensured the project stayed on track.
Results: A Green Belt Project Success
After 90 days of implementing the solution, the results were remarkable:
- 1,416 shipments between June 3, 2024, and August 30, 2024.
- Zero customer complaints.
- Zero dock audit findings.
- 0 PPM defect rate, achieving a process capability above six sigma.
These results not only met but exceeded the project’s goal. Financially, the project delivered $54,916 in savings, a significant win for Orbis Bardstown.
Sustaining the Gains: Controlling the Process
Lean Six Sigma emphasizes sustainability, ensuring improvements last well beyond the project’s end. At Orbis Bardstown, control measures included:
- Daily GEMBA meetings to review customer complaints and dock audit results.
- Regular monitoring of the lockable ID cabinet to prevent backsliding.
- Continuous reinforcement of team accountability for process compliance.
By focusing on both controlling key process variables (Xs) and monitoring outcomes (Ys), the team ensured lasting success.
Lessons from a Lean Six Sigma Green Belt Project
- Cross-Functional Teams Lead to Better Solutions
Including representatives from all key departments ensures a holistic approach to problem-solving. - Motivation is Key to Success
Addressing initial skepticism and fostering collaboration turned hesitant participants into enthusiastic advocates. - Simple Solutions Can Have Big Impacts
Using Lean Six Sigma tools like the fishbone diagram helped uncover the root cause, and a straightforward countermeasure delivered dramatic results.
Why Lean Six Sigma and Green Belt Projects Matter
This Lean Six Sigma Green Belt project at Orbis Bardstown showcases the real-world impact of structured problem-solving. By addressing a specific issue—defect reduction in product IDs—the project delivered measurable results in quality, customer satisfaction, and financial savings.
For professionals new to Lean Six Sigma, this case study highlights how these methods turn complex challenges into manageable, data-driven solutions. Whether you’re looking to solve a persistent problem, engage your team, or improve your bottom line, Lean Six Sigma offers a proven framework for success.
Start your Lean Six Sigma journey today—because every defect reduced brings you closer to operational excellence.
