Applying Lean Six Sigma: Personnel Reliability Program

Contributing USMA Research Unit(s)

Systems Engineering

Publication Date


Publication Title

Proceedings of the Annual General Donald R. Keith Memorial Conference

Document Type



The Personnel Reliability Program (PRP) monitors over 400 employees who handle controlled chemical or biological agents for the U.S. Army Combat Capabilities Development Command Chemical Biological Center (CCDC-CBC). The program requires an annual recertification consisting of a medical evaluation, safety training requirements, both in-person and online, and security clearance updates. The annual recertification process begins when a program administrator notifies a PRP enrolled employee to complete their recertification. The process is complete when administrators document the employee’s completion of all recertification requirements. Initial surveys revealed over 20% of employees were dissatisfied with the annual recertification process and over 30% of employees were dissatisfied with the instructions provided to complete the recertification requirements. A Lean Six Sigma study was performed to improve the recertification process and increase employee satisfaction. A secondary goal for the study was to decrease the average cost, per employee, of completing the annual recertification process.

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