Lean Six Sigma: Bridging the Gap Between Productivity and Safety Compliance

Adam Fox • 3 January 2024

A synergistic relationship where safety and efficiency reinforce each other

In the manufacturing industry, much like most industries, the pursuit of increased productivity and strict adherence to safety compliance often seem to be at odds. The pressure to maximise output can inadvertently lead to corners being cut in safety protocols, while stringent safety measures can sometimes be perceived as hindering productivity. However, Lean Six Sigma, a methodology focused on improving efficiency and eliminating waste, offers a compelling solution to harmonise these two critical aspects of manufacturing.


Harmonising Safety and Efficiency


The core philosophy of Lean Six Sigma revolves around streamlining processes, reducing waste, and enhancing quality. When applied thoughtfully, it can significantly improve safety compliance without compromising productivity. In fact, it can lead to a synergistic relationship where safety and efficiency reinforce each other.


One key concept in Lean Six Sigma is the identification and elimination of non-value-adding activities. In the context of safety, this can mean simplifying safety procedures without reducing their effectiveness, thereby making it easier for employees to comply and reducing the time taken in following these procedures.


Techniques for Balancing Safety Compliance and Productivity


Lean Six Sigma employs several techniques that are particularly effective in achieving this balance:


  • Process Mapping and Analysis: By mapping out processes, manufacturers can identify steps that contribute to safety risks or non-compliance. These steps can then be redesigned or improved to enhance safety while also making the process more efficient.


  • Root Cause Analysis: This technique involves identifying the underlying causes of safety incidents or compliance issues. Addressing these root causes often leads to process improvements that enhance both safety and productivity.


  • Standardisation of Processes: Standardising work processes not only ensures consistency in quality but also in safety practices. This standardisation reduces the variability that can often lead to accidents or non-compliance. It also makes policing adherence to processes and safety protocols much simpler and more effective.


  • Continuous Improvement: Lean Six Sigma encourages a culture of continuous improvement, where processes are regularly reviewed and improved. Something the HSE are keen to see in all industries, not just manufacturing. This ongoing process keeps safety and productivity at the forefront, ensuring that one does not improve at the expense of the other.


Case Studies Illustrating Successful Balance


Several manufacturing companies have successfully used Lean Six Sigma to balance productivity and safety compliance. For instance, a chemical manufacturing plant utilised Lean Six Sigma methodologies to redesign its material handling process. The new process not only reduced the time taken to handle materials but also significantly lowered the risk of hazardous spills, thereby, enhancing safety compliance.


In another example, an automotive parts manufacturer applied Lean Six Sigma to its assembly line. By analysing, simplifying, and improving their workflow, they reduced the amount of manual handling required by individuals and therefore reduced the physical strain on workers, decreasing the risk of injuries. The by-product of this process improvement was that it increased the number of units produced by a staggering 12%.


Challenges and Considerations


While Lean Six Sigma provides a framework for balancing safety and productivity, its implementation is not without challenges. The most significant of these is resistance to change. Employees and management alike may be sceptical about new processes, especially if they perceive them as adding more complexity to their work.


To overcome this, it's crucial for leadership to be involved and committed to the Lean Six Sigma initiatives. They should clearly communicate the benefits of these changes, not just for the company, but for the employees' safety and ease of work. Additionally, involving employees in the process improvement exercises can help in gaining their buy-in and making the transition smoother.


Conclusion


In conclusion, Lean Six Sigma offers a robust approach to harmonising safety compliance and productivity in the manufacturing industry. By focusing on process improvement, waste reduction, and continuous improvement, it provides a pathway for manufacturers to enhance their safety standards without sacrificing efficiency. As more companies adopt this methodology, we can expect to see a shift in the manufacturing landscape, where safety and productivity are no longer at odds, but rather, work in tandem to create a more efficient, safer, and more profitable manufacturing environment.


Transform Your Manufacturing Process with Consulo


As you've seen, the balance between maintaining rigorous safety standards and achieving optimal productivity is delicate but crucial. At Consulo, we specialise in turning this challenge into your competitive advantage. Our expertise in Lean Six Sigma methodologies uniquely positions us to help your manufacturing company not only identify areas where safety can be significantly improved but also enhance overall efficiency and profitability.


Imagine a workspace where safety and productivity coexist in harmony, where compliance is not a hurdle but a stepping stone to greater success. That's the environment we strive to create for you. Our team of experts will work closely with you to analyse your processes, identify key areas for improvement, and implement targeted strategies that bring about tangible, positive changes.


Don't let the complexity of trying to improve both compliance and efficiency slow you down. With Consulo, embark on a journey towards a safer, more efficient, and profitable manufacturing process.



Contact us today to learn more about how we can make this vision a reality for your business. Together, let's redefine what's possible in manufacturing!


Take the First Step Towards Excellence – Reach out to Consulo Now.


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by Adam Fox 9 April 2025
Asbestos and the Circular Economy: Why It's Time to Stop Burying the Problem Twenty-five years after asbestos was banned in the UK, we’re still digging a hole—literally and metaphorically. Every day, across the country, asbestos waste is double-bagged, labelled, loaded into skips, and driven to landfill, where it will sit indefinitely, taking up valuable space, creating ongoing liability, and adding to our already bloated environmental burden. And yet, 2025 presents a different path. A smarter one. One that replaces disposal with repurposing, and turns a dangerous waste product into a useful, circular resource. The technology exists. So the question we should be asking isn’t “Can we recycle asbestos?” It’s “Why the hell aren’t we doing it already?” Landfill is Failing Us—But We’re Still Relying On It Let’s start with the basics. There are still over 1.5 million buildings in the UK that contain asbestos, most of them now approaching the end of their useful life. As these structures age or undergo refurbishment, the volume of asbestos waste is only going to increase. Right now, we handle that waste the same way we did decades ago: • Identify it • Remove it (usually under fully controlled conditions) • Seal it in heavy-duty plastic • Drive it to landfill • Bury it • Forget about it Except we don’t forget, do we? Because landfill space is running out. Disposal costs are going up. And the environmental cost? We’re only just starting to count it. There’s a Better Way—and It Already Works Here’s what most duty holders don’t realise: We no longer have to bury asbestos. Thanks to recent advances in thermal treatment technology, we now have a method that can safely denature asbestos, breaking down its fibrous structure and rendering it harmless. Companies like Thermal Recycling in the UK are already proving this is not science fiction. They’re using high temperatures to transform asbestos cement products—like corrugated roofing sheets—into an inert ceramic material that’s completely safe. But here's the best bit: That material isn’t just neutral. It’s useful. It can be crushed and graded into aggregate, which can be used in road construction, paving, and concrete mixes. Instead of creating a waste burden for the next generation, we’re creating a valuable, low-carbon building material. Why Aggregate Matters in the Carbon Equation The production of virgin aggregates—through mining and quarrying—is energy-intensive and environmentally damaging. It contributes significantly to CO₂ emissions and destroys natural landscapes. So by replacing some of that demand with recycled aggregate from denatured asbestos, we: • Cut carbon emissions • Reduce dependence on extraction • Shrink the environmental footprint of infrastructure projects • Extend the life of quarries and reduce waste tonnage That’s not just a win for waste management. That’s a win for the entire construction supply chain. And yet most people in the industry don’t even know it’s possible. Why Are We Still Burying What Could Be Reused? As someone who’s worked in asbestos compliance for over 20 years—and now helps business leaders manage risk more intelligently—I’ve seen the same patterns play out time and time again: • “We’ll just do what we’ve always done.” • “This project’s tight on budget—landfill’s cheaper, right?” • “We’re just following the usual route—it’s less risky.” Let’s be honest. That mindset is outdated, short-sighted, and lazy. Cost may always be a factor, but the belief that landfill is “cheaper” needs to be challenged. Once you factor in: • Long-term environmental costs • Reputational risk • Rising disposal fees • And the public pressure for sustainable practices Thermal recycling is already starting to make sense. Especially when the output is something usable, not something buried. Licensed Contractors: You Don’t Get a Free Pass Either This isn’t just about clients or duty holders. Licensed Asbestos Removal Contractors (LARC’s) have a moral obligation here too. And I say that not from a place of opinion—but from first-hand experience, day in and day out for over two decades. Too often, LARCs put profits over progress. They default to landfill because it’s faster, easier to price up, and keeps their margins clean. They know the alternatives exist—but they don’t explore them, let alone offer them to their clients. When you hold a licence from the HSE, you’re not just a business—you’re a guardian of public health. That comes with responsibility. 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No one’s asking you to overhaul your entire waste strategy overnight. But you can—and should—start asking better questions: • “Is landfill our only option here?” • “Could this waste stream be recycled instead of buried?” • “What suppliers, contractors, or experts do we know who can help us explore this?” You don’t have to be a global pioneer. But if you’re in a position of responsibility, you should at least be aware that the old way isn’t the only way anymore. Final Thought: The Future Is Circular—Whether You Join In or Not Asbestos will be with us for decades to come. That’s a fact. But how we handle it—and whether we choose to keep repeating the past or do something smarter—is up to us. Thermal recycling and other denaturing technologies offer a rare opportunity to do something that actually moves the industry forward. Not just ticking the compliance box. Not just burying the problem. But solving it—and turning it into something useful in the process. If you’re involved in asbestos management in even the slightest way, ask yourself this: Are you part of the problem, or part of the solution?
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