Lincoln Industries

Chris Myers

At Lincoln Industries, our quest to develop a large group of problem solvers to strengthen quality throughout the company took a dramatic step forward eight years ago. In 2016, a new wave of quality and productivity improvements was initiated with a signature program called Ignite. At that time Green Belt was introduced to support the development of skills to make our people better leaders and problem solvers.

The initial group of six people who completed training allowed the company to apply lean Six Sigma Green Belt problem-solving to benefit the company and its customers. The idea of taking this to the entire workforce really took hold, leading to another wave of problem solvers and more participants and suddenly the Ignite program was born. An easy-to-use process improvement program, Ignite allows people throughout the company to quickly drive improvements in their area and provides recognition at an individual, team and area level.

The Ignite Program follows the DMAIC problem-solving methodology consisting of Defining, Measuring, Analyzing, Improving, and Controlling. We have since added a “Spark” card to capture some of the quick wins. Ignite projects are driven by people closest to the activity and their respective teams. With the stated goal of “developing problem-solving skills while also continuously improving the company,” Ignite has expanded outside of traditional areas like Operations and Quality, and into Accounting, HR, Shipping, and other support functions.

Quality, and into Accounting, HR, Shipping, and other support functions.

The process starts with the “Define phase” where our people define the problem and goal statement. We then move to problem-solving and root-cause analysis to find a solution to the problem with the yellow cards. The last step is to implement the improvement and track results with the blue card. After the blue card is completed, the project is considered complete. If a problem arises where the solution is evident, and implementation is all that is needed a Spark card can be used as a standalone process.

"At Lincoln Industries, our quest to develop a large group of problem solvers to strengthen quality throughout the company took a dramatic step forward eight years ago. In 2016, a new wave of quality and productivity improvements was initiated with a signature program called Ignite. At that time Green Belt was introduced to support the development of skills to make our people better leaders and problem solvers"

Just how popular are these Ignite projects? In our eighth year since launching the program, we are on pace to surpass our 2,000th project. We continue to have hundreds of Lincoln Industries associates participate to vie for the cash awards that are paid out to the top three projects each quarter. Key leaders in the company, including most of the Senior Team, serve as judges for the finalists. In 2022, we opened 240 projects and ultimately “closed” 209 of these. More than 200 people from 46 different departments were part of the various Ignite teams. Savings are measured in hundreds of thousands of dollars.

Lincoln Industries Vice President of People Resources, Scott Miller, counts Ignite as one of his favorite programs, pointing out that it introduces valuable Six Sigma principles to a broad range of people throughout the company. Miller, the former Corporate Controller, who now oversees HR and Culture, understands the value of ROI and is excited to see people connect the dots

“Our best and most impactful projects naturally start with our people,” said Miller. “When it comes to finding solutions to problems, who better to engage than those who deal with productivity opportunities every day.”

Miller also pointed out that many of the projects lead to important safety improvements. “We want people to leave the plant in the same condition in which they entered it. Ignite has produced countless projects that impact our people’s health and safety in positive ways.”

In addition to receiving recognition, cash prizes, and exposure to key leaders in the company, all participants are afforded an opportunity to feel like they are making a positive difference for the company and their teammates. The Ignite program has become such a part of our culture that we have a standing recognition segment at our annual service and recognition banquet called “Night of Champions.”

Founded in 1952 and headquartered in Lincoln, Nebraska, Lincoln Industries is the largest and most diverse privately held metal finishing company in North America with operational locations and facilities in Wisconsin, Minnesota, Texas, and Mexico. The company has over 1,400 team members in a 24/7 operation. It is known nationally for its culture and leading-edge wellness programs and has been recognized multiple times as a Great Place to Work by Fortune Magazine.