Above and Beyond

Six Sigma methodology is all about using data to make processes more efficient or economical, which fits right in with Monument always challenging customers and employees to imagine what’s possible. Recently, a Lean Six Sigma Yellow Belt project was completed remotely to optimize the purchase and inventory of raw materials used at the site.

Raw materials buyer Drew Esarey earned his Yellow Belt as a result of his involvement with the project, which began during the pandemic. “After a few late-night phone calls from the plant with concerns about very low product levels, we knew the ordering process could be improved,” he said. “The goal of this project was to minimize or eliminate potential ‘stockouts’ of raw materials on site, specifically Magnesol.”

After gathering six months’ worth of usage data, the team calculated how much Magnesol should be in inventory before being triggered to place the next order based on several factors. “The improvements to our process came from implementing a Kanban system,” Drew explained. “Kanbanis a Japanese word meaning ‘sign board.’ Kanbans are usually cards or other visual cues, and the one we implemented is a piece of neon green card stock placed on a certain numbered pallet of Magnesol.” 

By implementing this system, the team expects to have a more efficient ordering process that will also ensure adequate product supply is available on-site at all times.

Looking back on the project, Drew is thankful to have been nominated for the team and the opportunity to further develop his leadership and analytical skills. “My greatest learning was around just how important it is to have good data, especially data that is accurate and unbiased,” he said. “And at the risk of sounding cliché, another thing I learned is that it really does take a team to have a successful project. The team in our Polychem unit, our shipping team, and our Master Black Belt, Kent Steele, all helped throughout the process and their support was invaluable.”