Success Stories

Starbucks Recent Success using Lean 6 Sigma

Tuesday, August 4th, 2009

This recent article show how a service organization can be successful appling Six Sigma to their processes. Here Starbucks focused on just one of the seven types of waste “Motion” of the operator. I bet that this did not only impact the bottom line by decreasing the wait time for each customer but it let the employee focus on the customer more giving better service.

The Honeywell Experience*

Friday, June 26th, 2009

Bersbach Consulting LLC provides Six Sigma training coaching and support across Arizona, including the Tucson, Phoenix, Scottsdale, and Glendale areas. At this time we would like to thank our friends and clients for their support. If you have landed here looking for our Six Sigma training, coaching or support services in Tucson, then please follow this Six Sigma Training link.

At a chemical plant in Europe, Honeywell was losing profits at approximately $900,000 per year. The problems appeared related to a need to simplify the process flow.The problem studied and a new process implemented.

This led to a reduction of cycle time from 12 to 10 days plus a significant reduction in product travel distance from 300 to 14 Kilometers. Through these changes, the loss was reversed into a profit of $3.4 Million per year.

* William J. Hill and Willie Kearney, “The Honeywell Experience,”  Six Sigma Forum Magazine, February 2003, 34-37

How much are these problems costing you each year? Would you like to be able to cost-effectively deal with these issues and move more money to the bottom-line while also improving employee morale, customer service and customer satisfaction? Contact us!

If your business is located anywhere in the World including the US, Tucson, Oro Valley , Oracle, Phoenix, Glendale, and Scottsdale, Arizona or beyond and you would like to learn more about our Six Sigma training, coaching and support services please call Bersbach Consulting LLC at 1-520-721-2077 or SKYPE me  Now!

Process Improvement at BOC Edwards*

Friday, June 26th, 2009

Bersbach Consulting LLC provides Six Sigma training coaching and support across Arizona, including the Tucson, Phoenix, Scottsdale, and Glendale areas. At this time we would like to thank our friends and clients for their support. If you have landed here looking for our Six Sigma training, coaching or support services in Tucson, then please follow this Six Sigma Training link.

During economic downturns, chip manufacturers must walk a fine line between balancing costs and providing high quality product. In this industry, sophisticated processes use specialty gases and chemicals to fabricate semiconductor devices that must be consistently pure to avoid costly yield failures. BOC Edwards, a supplier of these gases, wanted to decrease costs while still maintaining high quality product.

They assembled a Six Sigma team to deal with this issue on one of the gases they produce. The results led to a dramatic reduction in the costs due to defects, and at the same time delivered improved gas by reducing the amount of impurity in the final product by 15.5%.

*Brian Zievis,” Process Improvement at BOC Edwards,” Six Sigma Forum Magazine, February 2003, 38-42

How much are these problems costing you each year? Would you like to be able to cost-effectively deal with these issues and move more money to the bottom-line while also improving employee morale, customer service and customer satisfaction? Contact us!

If your business is located anywhere in the World including the US, Tucson, Oro Valley , Oracle, Phoenix, Glendale, and Scottsdale, Arizona or beyond and you would like to learn more about our Six Sigma training, coaching and support services please call Bersbach Consulting LLC at 1-520-721-2077 or SKYPE me  Now!

The Bug and the Slurry: Bacterial Control in Aqueous Products:*

Friday, June 26th, 2009

Bersbach Consulting LLC provides Six Sigma training coaching and support across Arizona, including the Tucson, Phoenix, Scottsdale, and Glendale areas. At this time we would like to thank our friends and clients for their support. If you have landed here looking for our Six Sigma training, coaching or support services in Tucson, then please follow this Six Sigma Training link.

Warren/Amplex Superabrasives had a problem at one of its Asian customers—a high capacity manufacturer of data storage disks. Their customer reported a problem in the polycrystalline diamond (PCD) slurry they were being supplied was clogging the filtering processes. To compound the problem, a film of unknown origin was appearing after the clean-up step from texturing.

Their customer had no time to send back any samples. They had three days’ worth of texturing slurry left, before the product line would have to shutdown.

After working with the customer and another division at Warren, they trace the problem to bacteria in the slurry and found that they could quickly resolve the problem by pasteurizing the slurry.

In less than three days, they ID identified the problem, found a solution, produced a 400-bottle order of new pasteurized polycrystalline diamond slurry, and shipped it overseas and where it was received in time to keep their customer running

*Ron Abramshe, “The Bug and the Slurry:Bacterial Control in Aqueous Products,” American Society for Quality: Making the Case for Quality,
September 2007, www.ASQ.org

How much are these problems costing you each year? Would you like to be able to cost-effectively deal with these issues and move more money to the bottom-line while also improving employee morale, customer service and customer satisfaction? Contact us!

If your business is located anywhere in the World including the US, Tucson, Oro Valley , Oracle, Phoenix, Glendale, and Scottsdale, Arizona or beyond and you would like to learn more about our Six Sigma training, coaching and support services please call Bersbach Consulting LLC at 1-520-721-2077 or SKYPE me  Now!

Other Healthcare Successes:

Friday, June 26th, 2009

Bersbach Consulting LLC provides Six Sigma training coaching and support across Arizona, including the Tucson, Phoenix, Scottsdale, and Glendale areas. At this time we would like to thank our friends and clients for their support. If you have landed here looking for our Six Sigma training, coaching or support services in Tucson, then please follow one of these links  Six Sigma Online Training or Six Sigma Classroom Training.

SSM Health Care*

This St. Louis-based nonprofit health care system increased its market share to 18% over three years while three of its five competitors lost market share.

Saint Luke’s Hospital of Kansas City (SLH) *

Financial performance steadily increased for three years, and client satisfaction scores ranked Saint Luke’s 35th out of 4,500 hospitals nationwide.

Thibodaux Regional Medical Center*

At this Southern Louisiana acute-care facility, an accounts-receivable project increased cash flow by $2 million per year, inventory reduction achieved annual cost savings of $450,000, and a medication-management project decreased defects by 42%.

Baptist Hospital, Inc.*

Overall patient satisfaction for this Florida-based health care provider rose into the 99th percentile for several years; staff satisfaction rose from 47% to 84% over five years.

* Information from American Society For Quality (ASQ)
http://www.asq.org/healthcare-use/why-quality/case-for-quality.html

How much are these problems costing you each year? Would you like to be able to cost-effectively deal with these issues and move more money to the bottom-line while also improving employee morale, customer service and customer satisfaction? Contact us!

If your business is located anywhere in the World including the US, Tucson, Oro Valley , Oracle, Phoenix, Glendale, and Scottsdale, Arizona or beyond and you would like to learn more about our Six Sigma training, coaching and support services please call Bersbach Consulting LLC at 1-520-721-2077 or SKYPE me  Now!

Application of Six Sigma to reduce Medical Errors*

Friday, June 26th, 2009

Bersbach Consulting LLC provides Six Sigma training coaching and support across Arizona, including the Tucson, Phoenix, Scottsdale, and Glendale areas. At this time we would like to thank our friends and clients for their support. If you have landed here looking for our Six Sigma training, coaching or support services in Tucson, then please follow one of these links  Six Sigma Online Training or Six Sigma Classroom Training.

At Froedtert Hospital in Milwaukee, Wisconsin, errors with IV medication drips and laboratory processing and results reporting were causing serious problems related to effective patient treatment.

After diagnosing and quantifying the problem, a new process was implemented which had a significant impact on customer care. Level 1 discrepancies (<1 ml/hr) fell from 47.4% to 14%. Level 2 discrepancies (1-5 ml/hr) fell from 21.1% to 11.8% and level 3 discrepancies (>5ml/hr) fell from 15.8% to 2.9%.

Left untreated, these types of problems can result in poor customer care, longer treatment and recovery times, increased costs, and reduced profits.

*Cathy Buck RN MSN, “Application of Six Sigma to Reduce Medical Errors,” ASQ’s 55th Annual Quality Congress, Charlotte, NC, Vol. 55, No. 0, May 2001, pp. 739-742,  http://www.asq.org/qic/display-item/index.html?item=14740

How much are these problems costing you each year? Would you like to be able to cost-effectively deal with these issues and move more money to the bottom-line while also improving employee morale, customer service and customer satisfaction? Contact us!

If your business is located anywhere in the World including the US, Tucson, Oro Valley , Oracle, Phoenix, Glendale, and Scottsdale, Arizona or beyond and you would like to learn more about our Six Sigma training, coaching and support services please call Bersbach Consulting LLC at 1-520-721-2077 or SKYPE me  Now!

Toward Error Free Lab Work*:

Friday, June 26th, 2009

Bersbach Consulting LLC provides Six Sigma training coaching and support across Arizona, including the Tucson, Phoenix, Scottsdale, and Glendale areas. At this time we would like to thank our friends and clients for their support. If you have landed here looking for our Six Sigma training, coaching or support services in Tucson, then please follow one of these links  Six Sigma Online Training or Six Sigma Classroom Training.

The North Shore-Long Island Jewish Health systems were experiencing miscommunication and procedural problems in their lab work. After researching the problems and instituting new processes and procedures, the company reduced average lab test processing times enough to be able to increase processing volumes 43% without adding additional personnel.

In addition:

  • Processing and analysis error rates dropped from about 1 in 100 tests, to 1 in 300 tests.
  • Patient satisfaction ratings went up.
  • Improvements resulted in a positive financial impact of $339,000 a year due to increased revenue and cost reduction.

*Nancy B. Riebling, Susan Condon and Daniel Goprn, “Toward Error Free Lab Work”; Six Sigma Forum Magazine, (November 2004), 23, www.asq.org/qic/display-item/index.pl?item=19709

How much are these problems costing you each year? Would you like to be able to cost-effectively deal with these issues and move more money to the bottom-line while also improving employee morale, customer service and customer satisfaction? Contact us!

If your business is located anywhere in the World including the US, Tucson, Oro Valley , Oracle, Phoenix, Glendale, and Scottsdale, Arizona or beyond and you would like to learn more about our Six Sigma training, coaching and support services please call Bersbach Consulting LLC at 1-520-721-2077 or SKYPE me  Now!

Faster Lab Results Using Six Sigma and Lean*

Friday, June 26th, 2009

Bersbach Consulting LLC provides Six Sigma training coaching and support across Arizona, including the Tucson, Phoenix, Scottsdale, and Glendale areas. At this time we would like to thank our friends and clients for their support. If you have landed here looking for our Six Sigma training, coaching or support services in Tucson, then please follow one of these links  Six Sigma Online Training or Six Sigma Classroom Training.

Doctors at the Pocono Medical Center were hampered in their ability to treat patients due to not receiving lab results until late morning. Once the problem was identified, a project team outlined and implemented new procedures to speed the lab process.

Within about six weeks, doctors began to receive blood test results by 6 a.m. for critical care patients and by 7 a.m. for all other patients. Project results also extended outside of the laboratory, contributing to a decrease in overall patient length of stay for the medical center.

*Walter T. Hayes and Carmine J. Cerra, with Mary Williams, “Faster Lab results Using Six Sigma and Lean,” ASQ Making the Case for
Quality, http://www.asq.org/healthcare-use/why-quality/case-studies.html

How much are these problems costing you each year? Would you like to be able to cost-effectively deal with these issues and move more money to the bottom-line while also improving employee morale, customer service and customer satisfaction? Contact us!

If your business is located anywhere in the World including the US, Tucson, Oro Valley , Oracle, Phoenix, Glendale, and Scottsdale, Arizona or beyond and you would like to learn more about our Six Sigma training, coaching and support services please call Bersbach Consulting LLC at 1-520-721-2077 or SKYPE me. 

Faster Turnaround Time*

Friday, June 26th, 2009

Bersbach Consulting LLC provides Six Sigma training coaching and support across Arizona, including the Tucson, Phoenix, Scottsdale, and Glendale areas. At this time we would like to thank our friends and clients for their support. If you have landed here looking for our Six Sigma training, coaching or support services in Tucson, then please follow one of these links  Six Sigma Online Training or Six Sigma Classroom Training.

North Shore University Hospital in Manhasset, NY, was experiencing noticeable delays in bed assignment turn around time. This was becoming an ever-growing problem due to increased patient volumes caused by the aging of the local population.

After the problem had been identified and quantified, the Hospital set a goal to reduce the average turnaround time from 226 minutes to 120 minutes.

After an improved process was implemented, average turnaround times dropped to 69 minutes, resulting in improved patient service and satisfaction, improved employee morale, and much more efficient utilization of hospital resources.



*Angelo Pellicone, Maude Martocci, “Faster Turnaround Time,” Quality Progress, Vol. 39, No. 3, March 2006, pp. 31-36,
http://www.asq.org/qic/display-item/index.pl?item=20434


How much are these problems costing you each year? Would you like to be able to cost-effectively deal with these issues and move more money to the bottom-line while also improving employee morale, customer service and customer satisfaction? Contact us!

If your business is located anywhere in the World including the US, Tucson, Oro Valley , Oracle, Phoenix, Glendale, and Scottsdale, Arizona or beyond and you would like to learn more about our Six Sigma training, coaching and support services please call Bersbach Consulting LLC at 1-520-721-2077 or SKYPE me  Now!