Sample Case Studies Pertaining to Six Sigma and Business Excellence

• Six Sigma roll out at a Large Insurance Company in Canada (2004)

  Executive overview, Champions training and Green Belt training conducted. Diagnostic Survey was done to identify high impact improvement projects. Totally 12 Green Belt projects with saving potential of 0.48 Million CAD were taken up and completed resulting in ROI of 105 % on the initiative. Recurring IT infrastructure failures were reduced enhancing customer satisfaction level.

• Six Sigma rollout at a Large IT Service Provider in UK (2005)

  Business improvement opportunities worth 13.0 Million GBP identified against existing net profit of 5 Million GBP of the organisation. Innovative approaches of Lean and Six Sigma helped to achieve these savings.

• Lean and Six Sigma Roll out at Varroc Engineering, Aurnagabad and Pune (2004 and 2005)

  Rolled out Six Sigma in entire group at all functions in five multi locational plants saving 3.0 Crores INR within a year. Defects were reduced to less than 200 ppm from over 2000 ppm. Lean application reduced the cycle time and Inventory by 50 %.

• Process Improvement at M/S WIMCO (A Pat of ITC Group), Mumbai, Kolkotta, Bareli, Chennia, India(2009)

  Helped in turnaround through productivity improvement and cycle time reduction. Drastic cost and defect reduction achieved through Statistical Process Controls. Saving to the tune of 4 Crore INR.

• Statistical Process Control(SPC) Rollout at M/S Times of India Across all the Presses in India (2009 & 2011)

  Helped in drastic cost and wastage reduction through SPC application. Saving to the tune of 7 Crore INR.

• Six Sigma Rollout at M/S Times of India Across major Presses in India(2011 to 2014)

  Rolled out Six Sigma at five multi locational plants saving 38.0 Crores INR within three years. Breakdowns were reduced by 50%. Spares, energy and wastage were reduced through process optimization and design of experiments. Over 30+ dedicated Six Sigma professional were developed through 10 days training and its application.

• Six Sigma Rollout at M/S ESS DEE Aluminum Ltd. Across major Plants in India(2012 to 2014)

  Rolled out Six Sigma in entire group at all functions in five multi locational plants saving 14.0 Crores INR within two years. Breakdown, wastage, customer complaint and energy consumption were reduced in the range of 20 to 70 %.