Accelerating Results from Lean Six Sigma Projects with Rapid Action

Accelerating Results from Lean Six Sigma Projects with Rapid Action

30-Jun-2015 Rick Tucci Lean Six Sigma Download

Performance Snapshot Preview: A global mining and processing firm speeded implementation of solutions developed through a Black Belt-led Lean Six Sigma Project by equipping a frontline employee team to be “implementation champions,” saving more than $2M in raw materials costs while gaining another $2.3M in finished product yield in less than 60 days time.


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

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

Rapid Action Team Results


annualized reduction in reagent spending


annualized gain in finished product yield


additional ideas presented for future improvement

55 days

cycle time from team launch to wrap-up

Leadership Comment

"In our business there is no substitute for frontline operator knowledge. Rapid Action Tools combined with Lean Six Sigma analytical tools gives us a way to tap that knowledge efficiently and link solutions to defined metrics and results." – Master Black Belt

Learn more about the Rapid Action Toolkit

Are you interested in accelerating results and increasing engagement from your organization’s change management and continuous improvement initiatives? Take a look “inside the box” of the most reliable process available for rapid, team-based improvement.

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Rapid Action Team Engagement Toolkit

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