Healthcare: Patient Flow Improvements

In partnership with Philips Medical, the Lean Revisions team helped improve the patient experience and satisfaction scores at a notable hospital in Northern California. Over 9 months, the team trained over one hundred Lean Six Sigma Leaders, Yellow and Green Belts to re-engineer critical processes, and helped pioneer a culture of continuous improvement. The improvement teams executed a variety of projects that increased patient satisfaction scores, increased patient flow and hospitalist capacity. The hospital saved $15 million by the time our team rolled off the second phase of the engagement.

Construction: Reducing Tooling Cost

During the first phase of a project with a quality window and door installation company, Lean Revisions managed to reduce their industrial tooling cost by $20,000. Within 3 months of the project, other major improvements were implemented and in place. These improvements secured the company a 30% reduction in their tooling budget. Six team leaders became accountable for the improvements, and in no time work crews had found other ways to reduce waste with consumable materials out in the field.

Manufacturing: Elimination of First Pass Defects and Capacity Increase

A Tier 1 supplier within the automobile industry was experiencing a first pass failure rate of 94% and reducing this will increase throughput and revenue at the same time. After conducting Lean training of twelve employees for 8 weeks the improvement team increased throughput capacity and generated $720,000 of new realized revenue per year, decreased first time failure rate from 94% to 6% for an annual realized savings of $957,000.00.

Finance

A major financial institution was experiencing a daily issue that misrouted over 1500 customer home loans, credit cards, auto and other payments to back-office operations. The misrouted items negatively impacted customer FICO scores, payment posting and experience. Our team led a 6-week enterprise project with twenty operations leadership members and re-engineered the end-to-end processes and procedure to reduce complexity and streamline the system. The improvement project reduced the daily misrouted items to 110, eliminated $880,000 of monthly courier expedite cost and immeasurable customer FICO score impact.

Supply Chain: Increase APAC Global Tier 1 and Tier 2 Apparel Capacity

During the 3-month engagement the Lean Revisions team trained over one hundred logistic specialists and visited multiple Tier 1 and 2 suppliers in China, Hong Kong, Jakarta, and Vietnam. The engagement resulted in a supplier capacity increase from 74% to 86%, supplier quality defect reduction of 20% and operations cost reduction of $15,000,000.

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“Anyone who knows #leansixsigma knows that once you learn about it you can’t stop using it. I have been using it since my days at WWU, and can’t wait to continue practicing in my professional (and personal) life!”

Jessica Reed

ASQ CSSYB, Manufacturing & Supply Chain Professional

” A timely and valuable topic. The cultural aspects of a continuous improvement mindset is often neglected in favor of implementing tools, so this is a good introduction to those looking to start or revive a continuous improvement program. “

Dr. Mark C.

Principal, Process Excellence Partners LLC

” I am thrilled and proud to say I have earned my ASQ Certified Six Sigma Yellow Belt! Through the Lean Revisions / Bellingham Technical College’s yellow belt course, I was able to hone my skills and understand what it takes to be certified. “