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PolyOne Corporation

In 2011, PolyOne embarked on a journey to transform our operations through a program we termed the PolyOne reliability program (PRP). The goal of the program was to improve operational supply reliability to our customers through improved on time delivery and increased facility longevity while maintaining world-class safety standards. In addition, significant effort was placed on best practice sharing, increased operational equipment efficiency (OEE) and the reduction of maintenance related expenditures.

A strong business case was developed with executive leadership engagement that facilitated buy-in throughout our organization, which at the time consisted of 46 sites. Through extensive benchmarking and utilization of Lean Six Sigma skills and resources, we identified performance gaps and developed an implementation strategy to address them. The rollout plan, known as the "playbook," was in the form of waves, where a group of sites were brought together for one week of training and then returned back to begin the transformation at their respective locations. Sites took ownership and responsibility for their implementation plan and were supported by corporate to ensure consistency and speed of execution.

In 2013, PolyOne added over 30 additional sites through a series of acquisitions. With the PRP wave implementation strategy and related action plan, we have been able to quickly incorporate these new locations. We now have 55 sites implemented with three more waves planned within the next year that will result in the complete integration of our organization.

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