1st Edition
Operational Excellence in the Process Industry A Practitioner’s Guide to Lean Six Sigma
Foreword
Preface and Acknowledgements
Disclaimer
Authors
1. Introduction: A Case for Change
2. The What and Why of Lean and Six Sigma
3. How Important Is Quality?
4. Lean Principles
5. Lean Tools
6. Summary of the Lean Principles and Strategic Outcomes
7. Advice for the Leaders
8. Sustainability and Operational Excellence: Aligning Lean with ESG Goals
9. Digital Transformation in Operational Excellence
10. Lessons from the Pioneers
Appendix 1: DPMO vs. Sigma Level
Appendix 2: Safety Factor
Appendix 3: Batch and Continuous Processes
Appendix 4: Chemical and Pharmaceutical Manufacturing—Similarities and Differences
Appendix 5: Commonly Used VSM/MIFA Icons
Glossary and Acronyms
Index
Biography
Habib Siddiqui is a globally recognized expert in Lean Six Sigma (LSS) and operational excellence, with nearly four decades of experience across the chemical, pharmaceutical, and process industries. Over his long career in corporate America—including almost three decades of leadership in operational excellence—Dr. Siddiqui has driven enterprise-wide transformations at BASF, Merck & Co., Rohm and Haas (now Dow), and Witco (now Chemtura), delivering significant business value and building enduring cultures of continuous improvement.
Before retiring in February 2026 from his role as a Senior Expert at BASF, the world’s largest chemical company, Dr. Siddiqui spearheaded major operational excellence initiatives across 95 manufacturing plants worldwide. His leadership helped embed sustainable continuous improvement, disciplined problem-solving, and capability development at a global scale. A certified Master Black Belt and widely regarded as a “grandmaster” of Lean Six Sigma, he is known for his strategic insight, hands-on mentorship, and ability to translate organizational vision into measurable outcomes. Following his retirement, Dr. Siddiqui continues to share his expertise through writing, consulting, and thought leadership. His work—spanning manufacturing, R&D, engineering, and business processes—continues to shape best practices across the process industries, leaving a lasting legacy of excellence that influences multiple generations of practitioners.
Hassan Siddiqui is an Expert Consultant at Boston Consulting Group (BCG), specializing in manufacturing excellence and sustainable operations. With a career spanning multiple industries, he has led initiatives that enhance operational efficiency, drive innovation, and support corporate sustainability goals. A Six Sigma Master Black Belt, Hassan brings deep expertise in process improvement and business transformation.
Prior to joining BCG, Hassan held a variety of roles at BASF, where he focused on asset effectiveness and product management across North America. His current work centers on helping global corporations transition toward Net Zero emissions by rethinking business design, optimizing supply chains, and implementing decarbonization strategies. Hassan holds an MBA from Duke University’s Fuqua School of Business and a degree in Chemical and Biomolecular Engineering from the University of Pennsylvania.
