Empowering Teams: 2024 Lean Six Sigma Workshops at Francesville and Flat Rock

US Aggregates® Lean Six Sigma workshops aim to empower plant workers by providing essential Lean tools and training. These workshops began this winter and were designed to create an environment where everyone is encouraged to question current operational practices and think critically about their work processes. Lean is a philosophy focused on continuous improvement and waste elimination, with roots tracing back to Henry Ford’s flow production in 1913 and further refined by Toyota in the 1930s. 

US Aggregates Director of Operations Kristin Sweeney and Master Black Belt Jim Massoels with The Heritage Group’s Business Excellence team will teach these classes and incorporate cross-functional collaboration across miner positions. Kristin recommends organizations interested in Lean Six Sigma start small. “Lean is practical and has a variety of applications, making it a valuable approach for continuous improvement and operational efficiency,” said Kristin. 

Recently US Aggregates successfully hosted workshops at its Francesville and Flat Rock locations. Workers from various plants came together to learn Lean principles and gain hands-on experience in the locations’ site shops. These immersive sessions allowed participants to engage in practical projects, enhancing their understanding and application of Lean principles. Employees, nominated by their managers, gained valuable insights into key Lean tools and techniques, including Lean terminology, the eight buckets of waste, 5S, visual management and root cause analysis. 

In addition to the core Lean principles, the workshops highlighted the importance of teamwork and effective communication. Participants learned how to share their insights with coworkers and apply this knowledge at their respective plant locations, which encourages a collaborative approach to problem solving. This cross-functional collaboration is crucial for identifying inefficiencies and developing innovative solutions that can be implemented across the organization. 

The workshops included case studies and real-world examples to illustrate the practical applications of Lean tools and techniques across an array of industries. Participants will have the opportunity to work on projects at their own sites over the next six months. This hands-on approach will not only reinforce the training but also help to build a sense of ownership and accountability among employees. 

Looking ahead to 2025, US Aggregates plans to expand these workshops to more plant locations. This initiative highlights US Aggregates’ commitment and investment into fostering a culture of continuous improvement and operational excellence across plant locations.