Lean six sigma is a business improvement methodology which combines tools from both lean manufacturing and six sigma. Lean manufacturing focuses on elimination of waste and thus increases overall speed of the process/operations. Six sigma focuses on quality. By combining the two, the result is better quality, cost efficient, faster and optimized process. Lean six sigma has not been used in recycling to the extent it has been in manufacturing. The objective of this research is to investigate the application and benefits of lean six sigma in the recycling industry. Specifically, the objective of the project is to improve the process for material recovery facility at Toledo, Ohio. This includes aligning and optimizing processes and the removal of process generated defects and errors.
This thesis revealed the current sigma level, defects per million opportunity and performance at Material Recovery Facility (MRF), Toledo. The case study of material recovery facility at Toledo is discussed. Defects per million opportunities are calculated from the on-site data collection. Using six sigma and statistical quality tools total tons processed per year, standard processing time, current sigma level, and total tons defective and financial aspect are discussed in the thesis.