Going Beyond Six Sigma and Lean Manufacturing

Change your Business Culture to Achieve Profitable Growth

In an organization undertaking a lean transformation and striving for operational excellence and continuous improvement, leadership’s role is even more critical, since many lean-leader attributes are not taught in business schools, nor are they intuitive. When rolling out an improvement effort, executives are initially excited by the early returns from low-hanging fruit, but many quickly become disenchanted when the pace of improvement weakens or pauses. 

Zero Loss Thinking

“Zero loss” thinking identifies where to focus your improvement activities. Zero-based thinking is a performance management mind-set in which there is no acceptable level of failure: no off quality, no breakdowns, no delays, no customer complaints, no manufacturing wastes, etc.

Through this systematic approach of uncovering root causes of less-than-optimized work streams our clients have achieved an ROI performance of 8 to 1 within 2 years of beginning an implementation.

Milliken Performance System

Like other business management strategies, such as Six Sigma and lean manufacturing, the Milliken Performance System helps businesses increase productivity, quality, and efficiency. But the Milliken Performance System’s distinction is that it changes the entire business culture by engaging everyone, resulting in long-term, holistic, sustainable improvement.

The Milliken Performance System promotes the goal of reducing defects, breakdowns, waste and other abnormalities to almost “zero” as the expected norm. The system is characterized by a foundation of safety and strategic clarity and is supported by 9 pillars which continue to drive Milliken to be a lean enterprise.

By implementing the Milliken Performance System, you can dramatically improve your operational performance and employee engagement.

Start the Change

System is built to focus on:

  • Properly managing equipment
  • Improving associates’ skills and knowledge
  • Preventive and predictive maintenance

Six steps of transformation:

  • Accommodate, educate, and demonstrate
  • Assessment
  • Master plan
  • Plant implementation plan
  • Model within plant
  • Replication

Case Study

Chemical Plant Embraces a Holistic Operating System

Read this case study to learn more about how a multi-billion dollar, global chemical firm systemized best practices and realized a 4.5-to-1 return on investment working with Performance Solutions in the first year.

Case Study

Packaging-Product Plants Implement Performance System

Read this case study to learn more about how a $3 billion packaging-products manufacturer improved breakdown performance, reduced minor stops, and reduced breakdowns by 50 percent or more.

Performance Solutions by Milliken

Since our 1865 founding, a commitment to continuous improvement and safety has been the foundation of Milliken & Company’s success, and we’ve spent the past two decades scouring the globe to discover the best ways to work. We recognize that best practices aren’t just limited to one industry, that’s why we’ve studied them all. We’ve looked, listened, and learned; and we’ve used the knowledge we’ve gleaned to develop our own holistic approach to improve efficiency and productivity based associate engagement and to incorporate lean manufacturing concepts.

Milliken has developed proven performance systems in both operations and safety that can help companies like yours improve their outcomes by using best methods. These methods— based on total employee engagement, efficient manufacturing processes, redefined metrics and practical expertise are transferable and customizable. You can expect improved productivity and a return on investment using these systems that have been our company’s compass and foundation for more than two decades, in more than 40 Milliken sites worldwide.


Performance Solutions by Milliken