Lean Six Sigma Consulting

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Maximize Efficiency and Quality with Lean and Six Sigma Integration!

Lean Six Sigma integrates lean methodologies with robust and advanced Six Sigma statistical tools to transform your manufacturing operations. We deploy selective Lean manufacturing tools to eliminate waste and enhance process efficiency, along with Six Sigma techniques to reduce defects, variations and improve quality.

Our comprehensive Lean Six Sigma approach, which includes current state assessment, data-driven decision-making, selecting right tools and strategies and gemba implementation helps you quickly deliver results, reduce complexity and boost productivity.

With our extensive experience in implementing the right Lean Six Sigma tools, training shopfloor teams for seamless adoption, and fostering a sustainable environment, we help you achieve maximum benefits while minimising costs.


Benefits of Implementing Lean Six Sigma

Improve quality by reducing variations and defects

Enhance efficiency, productivity by eliminating waste

Accelerate complex problem solving using statistical data

Reduce costs by reducing operational lead time

Our Impact in Lean Six Sigma Implementation

0 % -20

Cost Reduction

0 % -50

Reduction in defects & Material losses

0 % -30

Reduction in lead time

+ 0 % +30

Improvement in manpower productivity

DMAIC Approach of Lean Six Sigma Implementation

DMAIC (Define, Measure, Analyze, Improve, Control) is the core methodology within Lean Six Sigma, providing a structured approach to problem-solving and process improvement. By focusing on data-driven decision-making and root cause analysis, DMAIC helps organizations achieve higher productivity, cost savings, and customer satisfaction. Its systematic framework not only drives incremental improvements but also ensures sustainability by implementing effective control mechanisms.

Define Phase
  • Identify the problem focussing on key impact areas
  • Develop a Project Charter outlining objectives, key metrics, scope, and business impact
Measure Phase
  • Map the process using Process Maps or Value Stream Maps (VSM)
  • Collect and analyze baseline data
  • Prioritize critical inputs using the Cause and Effect (C&E) Matrix and FMEA
Analyze Phase
  • Identify root causes using Multi-Vari Analysis, Root cause analysis
  • Test assumptions and validate root causes using Hypothesis Testing
Improve (Execute) Phase
  • Generate solutions through brainstorming
  • Test and validate improvements using Design of Experiments (DOE), pilot studies, or simulations
Control Phase
  • Develop a Control Plan with Statistical Process Control (SPC) and Control Charts
  • Standardize processes through layered audits and Standard Work to sustain improvements

Deployment of Lean Six Sigma

1. Deployment Planning

Create a common understanding of Lean Six Sigma and define tangible & cultural goals to be achieved from Lean Six Sigma deployment.

2. Lean Six Sigma Training

Training-cum-Workshop to provide an overview of the fundamentals of Lean Six Sigma concepts and to identify & define improvement projects.

3. Build Internal Capacity

Relevant training to equip the team with the technical and conceptual knowledge of problem-solving tools and certify them as Yellow Belt, Green Belt, and Black Belt.

4. Execute Improvement Projects

Implement Lean Six Sigma using DMAIC methodology and apply right lean and six sigma tools to execute projects successfully with desired results.

5. Sustain and Standardise

Conduct weekly projects reviews & results tracking, monthly Steering committee meetings, reward & recognition system for long term sustainability.


Our Experience in Lean Six Sigma Implementation

0 + 100

Clients

0 + 50

Industries

0 + 1000

Successful Projects

0 x 20

Return on Investment

Lean Six Sigma Training Certification

Master Lean Six Sigma with our comprehensive Lean Six Sigma training programs designed to drive operational excellence, reduce waste, and enhance quality. This training empowers your employees with Six Sigma tools, techniques and Lean methodologies by certifying them as Yellow Belts, Green Belts, and Black Belts, each level representing a deeper understanding and capability in process improvement.

What to Expect

Expertise

Our customized lean six sigma implementation approach with the right tools, training and continuous improvement expertise ensure that your teams have the right data and skills they need to extract maximum benefits from lean six sigma implementation.

Engagement

Our lean six sigma consultants engage all levels and functions in an organization to identify and reduce non value adding activities through Lean tools and reduce variations to improve quality using Six Sigma tools.

Accountability

A vital part of our lean six sigma consulting is to develop the abilities of top managers, continuous improvement leaders, and transformation managers to lead change in their organizations.

Impact

Combining lean six sigma tools with our lean six sigma consultants expertise helps organisations reduce defects by more than 50%, reduce throughput time by 30% and improve manpower productivity by 40%.

Integrating Lean manufacturing principles with Six Sigma tools and techniques enables companies to reduce lead time, enhance productivity, reduce defects and thereby improve overall profitability.

Our Clients Results

CASE STUDY

Aluminium cold rolling mill reduces casting defects, white rust rejections and melt loss through Lean Six Sigma

Lean Six Sigma

An aluminium mill improved quality, yield and cost through Operational Excellence, cutting overall casting rejection, reducing superficial line and temper-related defects delivering significant financial gains driven by cross-functional, data-led problem solving with shop-floor validation, experiments and standardisation.

Consulting Services

Connect with our Experts!

With experience across diverse industries and challenges, we deliver unparalleled insights and solutions especially designed as per the needs. For more details, contact us today!

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