Situation

A global Fortune 500 fertilizer mining and processing company needed to leverage its small cadre of Black Belts and achieve faster deployment of Lean Six Sigma project solutions.

Team Engagement Strategy

A small team of frontline employees was briefed on Black Belt conducted analyses and then equipped with Rapid Action, an “all in one” team engagement toolkit for accelerating results, to convert these analytics into improved performance.

Rapid Action Project Charter

How can we improve the process for adding reagents to raw materials in order to reduce cost and consumption levels used in fertilizer processing without incurring a loss in product quality or yield?

Sample of Solutions Implemented

1. Steam cleaned reagent lines to improve flow of reagents into mixers.
2. Wrote new procedures to standardize cleaning of reagent lines to maintain effectiveness of flow.
3. Improved mixing equipment performance by patching leaks.
4. Standardized equipment maintenance procedures across multiple shifts.
5. Trained operators to use refract-o-meter to test for proper mixing of reagents.