Power plants are a necessity of modern life and exist in every country in the world. Lean and Six Sigma help in the operation of the power generated. We’ll look at applications in India, Zimbabwe, and Iceland and finish with a video of how a geothermal power plant works.


Six Sigma Applied to Improve the Performance of a Thermal Power Plant: India


In a case study titled “Implementation of Six Sigma for Improved Performance in Power Plants,” authors T. Sudhakar, B. Anjaneya Prasad, and K. Prahladarao discuss the use of Six Sigma to optimize de-mineralized water consumption in a thermal power plant.

The case study includes:

  • High-level Process Map for Cycle Make Up Water Consumption
  • De-Mineralized (DM) Water Consumption Stats in Stage I
  • Run Chart of Stage I
  • Capability Analysis of DM Stage I
  • Fishbone Diagram for More DM Cycle Make Up
  • Bar Chart of DM for Stage I
  • Pareto Chart for DM Leakage Stage I
  • Action Plan for Improve and Control Phases
  • Before/After Capability Comparison for DM Regenerate

You can read the case study here.


Using Lean Tools to Reduce Maintenance Costs in A Coal Handling Plant: Zimbabwe


In a case study titled “Application of Lean Tools in Planned Maintenance: Case Study of a Coal Handling Plant at a Thermal Power Station” authors Isaac Chinhengo, William M. Goriwondo, and Blessed Sarema discuss the use of Lean tools to reduce maintenance costs.

The case study includes:

  • Maintenance Strategies
  • Wastes in Maintenance
  • Maintenance Activities
  • Coal Handling Plant Planned Maintenance Current State Map
  • Proposed Improvements and Recommendations
  • Pareto Chart of Activities
  • Coal Handling Plant Planned Maintenance Future State Map

You can read the case study here.


Analysis of Methods Applied to the Maintenance of Geothermal Power Plants: Iceland


In a master’s thesis titled “Analysis of management methods and application to the maintenance of geothermal power plants,” author Clety Kwambai Bore discusses the use of Lean, Six Sigma, and various maintenance methods in order to determine a methodology that can optimize the maintenance of geothermal power plants.

Clety compares Reliability Centered Maintenance, Lean, and Six Sigma in the maintenance of geothermal steam gathering systems.

The included FMEA found most maintenance problems in geothermal power plants are related to the chemical and physical properties of the geothermal fluids.

You can read the thesis here.


How Does a Geothermal Power Plant Work?: Chile


This video from the Andean Geothermal Center of Excellence shows how a geothermal power plant works.


You can watch the video here.



Advance your knowledge of Six Sigma and join ISSSP today! Access the hundreds of interviews, webinars, whitepapers, case studies, and other resources available in our online library.

Learn More Here