Operational Excellence for Chemicals and Plastics
Stable recipes, less scrap and faster changeovers. For chemicals, coatings, plastics and packaging manufacturers in Greece, Cyprus and Europe.
- Process stability
- Fast changeovers
- Less material wasted
Why operational excellence matters
In chemicals and plastics, batches, recipes and machine settings decide quality. Small variation in raw materials or settings leads to scrap, rework and complaints.
Greece Lean Six Sigma helps plants stabilise critical parameters, cut changeover times and measure the real yield of materials and energy.
Where we help
Batch consistency
Recipes, raw materials, critical parameters and variation analysis.
Colour and mould changes
SMED, cleaning, sequencing and start-up losses.
Scrap and rework
Defects, regrind, investigations and prevention.
Energy and resources
Energy, water, steam and compressed air consumption.
Safety and environment
Standard work, FMEA, risk management and waste.
Inventory and planning
Raw materials, work in progress, SKUs and customer service.
Common operational challenges
- Batch to batch variation
- Long changeovers
- High start-up scrap
- Recurring defects
- High energy use
- Many SKUs and small batches
- Excess inventory
- Customer complaints
- Waste and regrind
- Settings that depend on the operator
Our approach starts from the process, not from an off-the-shelf training course. We find where performance is lost, quantify the opportunity and choose the method that fits the problem.
From diagnosis to improvement
- Understand the processWe review flow, roles, data and controls.
- Set the baselineWe quantify performance with the right indicators.
- Find the dominant lossesWe focus on the problems with the biggest impact.
- Choose the right methodQuick win, Kaizen, root cause analysis, DMAIC or redesign.
- Sustain the resultWe build ownership, control, capability and daily management.
Typical performance indicators
Choose your starting point
Operational Excellence Diagnostic
Assessment of one process or value stream, with a prioritised map of improvement opportunities.
In-company training
A programme tailored to your sector, in a classroom or Live Online, with examples from your own operation.
Targeted improvement project
Lean Six Sigma applied to one specific problem, with a measurable result.
Related training
Frequently asked questions
How is scrap reduced in injection moulding?
We combine analysis of machine parameters, MSA on measurements and experimentation to find a stable operating window.
Is improvement linked to sustainability?
Yes. Less scrap and energy means less waste and fewer emissions. The Lean + Green programme makes this measurable.
Do you always start with training?
No. We start from the process. First we find where time, quality or cost is lost and what it costs. Then we choose a quick win, Kaizen, a DMAIC project or team training.
Can the training run in-house?
Yes. Programmes run in-company, in a classroom or Live Online, with examples from your own operation.
Where do you work?
We work with organisations in Greece, Cyprus and Europe, in Greek or English.
Start from the process.
Find the opportunities. Quantify the losses. Prioritise the improvements.