A site has 100 maintenance employees that average 3.5 hrs/day of tool time. Six Sigma determines the rest of the time is ordering parts, gathering tools, etc. Response: hire one maintenance planner, one stores person to kit parts and one maintenance purchasing agent. Total cost $ 300K, Maintenance no longer ordering and securing parts, etc. Tool time increases to 6.8 hours a day. Lay off, or allow to bump 40 maintenance workers at $ 90,000 a year. Spend $ 300K to save $ 3,600,000. Stay lean baby!
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