Engineer saves $800K on Black Belt project to increase capacity and reduce hazardous waste

A film manufacturer was looking to increase efficiency and reduce costs when replacing the membrane filters in their tanks. The downtime caused production delays and negatively impacted capacity. The engineer supporting this process completed her Black Belt training and I helped coach her on her project. After conducting designed experiments to see how long the filters can last, she was able to extend the life of the filters 400% longer than the current duration, which reduced downtime and reduced filter replacement costs. During filter replacement, organic solvent is flushed and captured as hazardous waste.

The project was able to reduce filter membrane replacement costs, increase production capacity and reduce organic solvent hazardous waste disposal costs, resulting in over $800K USD savings.