Industrial emissions to the environment have an adverse impact on public health. Pollution Prevention (emissions reduction at the source) has been promoted by US-EPA. There are perceived barriers to effective implementation of Pollution Prevention including cost, technical support and a regulatory preference for end of pipe treatment. An approach to Pollution Prevention is needed that will reduce the impact of these perceived barriers.

Six Sigma and Lean are business process improvement methodologies successfully utilized in diverse industries. Six Sigma focuses on quality, eliminating defects through reduced variation and enhanced understanding of the impact of process variables on key output variables of importance to stake holders. Lean improves speed and efficiency resulting in the reduction/elimination of waste. Six Sigma and Lean have been integrated by numerous and diverse organizations as Lean Six Sigma.

The purpose of this research is to determine if Lean Six Sigma is an effective approach to Pollution Prevention. Two industrial processes at a chemical manufacturing facility in the Midwest were selected for study. By utilizing the tools of Lean to reduce waste and improve cycle time combined with Six Sigma to better understand the effect of operating variables on the process, the discharge of copper, a metal toxic to aquatic microorganisms was eliminated. Eliminating the use of copper also reduced cost, increased process capacity and eliminated a potential ergonomic risk. The reduction in copper emissions required less than one month from conceptualization to implementation. Rapid implementation is typical of a Lean initiative.

The second project reduced natural gas consumption at a process flare used to control emissions from several chemical processes. Utilizing Lean Six Sigma tools, natural gas consumption was reduced by 50% and annual emissions of carbon dioxide were reduced by 4,000.000 pounds, carbon monoxide by 15,800 pounds and nitrogen oxides by 3000 pounds. The cost of implementation had a payback period of less than three months.

The dissertation concludes by discussing implications for public health research and future research needs. Achieving pollution prevention through the application of Lean Six Sigma provides industry with a proven approach to achieve economic as well as environmental stewardship objectives.