An Integrated Lean and Six Sigma Framework for Improving Productivity Performance: A Case Study in a Spanish Chemicals Manufacturer

Abstract

In the pursuit of operational excellence and enhanced competitiveness, a wide range of industries have turned to methodologies such as Lean and Six Sigma; however, in the chemical sector, their application is very limited. This paper presents a Lean Six Sigma framework to identify and reduce sources of variability occurring in the final product composition of a Spanish SME fertilizer manufacturer. The company faced important challenges related to product variability, adversely affecting overall productivity. A real-life case of the Lean Six Sigma implementation was conducted over two years, and its applicability and ability to improve productivity performance were thoroughly assessed. The proposed framework successfully integrated Lean and Six Sigma methodologies, i.e., process mapping (value stream mapping), root cause analysis (Ishikawa cause–effect diagram), project management (SIPOC and DMAIC), and statistical process control, and demonstrated practical benefits for the case company by identifying the key variables affecting product variability and determining their optimal levels. A substantial 50% reduction in the variability of several products and a 42% reduction in material preparation time were achieved. These reductions resulted in a 40% reduction in costs associated with product losses and a 54% reduction in costs from raw material losses.