6 Sigma Case Study Ppt Examples

Lean and Six Sigma Case Studies

We have picked some of our projects to show as Lean and Six Sigma case studies.

We have conducted a huge variety of Lean Six Sigma projects across the World. Projects have been conducted in many fields and many industries. Some projects are short and sweet while others have taken many months to complete. Some have been complicated with multiple obstacles and others have been fairly simple.

Here, we have tried to pick projects that cover a good spectrum between industries and difficulty levels, etc.

We hope the case studies below can give you a good idea of how versatile Lean Six Sigma is. Hopefully, they may also give you some ideas on how to conduct your own Lean Six Sigma projects.

Case Study #1 - Formed Helical Wires for Japanese Market
Looks at how our client's factory was able to break into the Japanese market by using the DMAIC process.

Case Study #2 - Inventory Reduction for Drilling Fluids Company
Looks at how we were able to drastically reduce inventory levels for our client in the oil and gas industry.

Case Study #3 - Productivity Improvement for Steel Hardware
Looks at how we increased productivity for a steel hardware manufacturing company. Capacity was increased with no extra investment.

Case Study #4 - Cost Reduction Through Capability Studies
Looks at how product cost was easily reduced for a company producing formed steel wires. It is a good example of how easily simple tools can help you cut cost.

Case Study #5 - Handling Time Reduction at Call Center
Looks at how our client, a call center, was able to greatly reduce the average handling time of inbound calls.

Case Study #6 - Reduction of Days Sales Outstanding
Looks at a large oil and gas company which had taken over multiple smaller companies over the years and was planning to acquire even more. Due to this, it was extremely important for them to increase their cash flow.

Case Study #7 - Online Top-Up for Prepaid Cellular Service Provider
Looks at a cellular service provider's problems with their online top-up system and how the DMAIC process was used to fix it.

Case Study #8 - Statistical Survey Analysis for Improvement
Looks at how a call center used statistical techniques to analyze survey results to find conclusive answers on the actions to be taken to increase customer satisfaction.

Case Study #9 - Aluminum Casting Lead Time Reduction
Looks at how a company that manufactures aluminum castings was able to increase efficiency and reduce production lead times by using Lean principles.


More Lean Six Sigma case studies will be added regularly, so make sure to come back often to keep up with them!


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Six Sigma projects can bring benefits including increased organizational efficiency, improved customer satisfaction, reduced costs, increased revenues, and more.

The Certified Six Sigma Black Belt Handbook reports that many Six Sigma Black Belts “manage four projects per year for a total of $500,000–$5,000,000 in contributions to the company’s bottom line.” A 2012 study of 28 organizations showed that “effective implementation of Six Sigma led to … an average return of more than $2 in direct savings for every dollar invested.”

The following case studies provide a closer look at results organizations have achieved using Six Sigma. Click here to browse other Six Sigma case studies; you can also find more examples of success in quality by visiting the ASQ Knowledge Center.

Supply Chain Techniques Applied to Six Sigma Saves SeaDek Marine Products $250,000– August 2016
SeaDek used supply chain techniques and Six Sigma to reduce major inventory stockouts in 2015. Inventory control tools were applied using DMAIC methodology. The company went from 14 major stockouts in 2014 to one stockout in 2015, resulting in a materials cost savings of more than $250,000 and improving on-time delivery from 44 percent the previous year to 95 percent in 2015.

YMCA Upgrades Day Camps Using Six Sigma – January 2016
When a senior leader at the YMCA of the USA introduced Six Sigma to the youth development department, a new method for managing and tracking projects was ushered into the organization. Upon completing a Green Belt-level training course, a YMCA project team used Six Sigma tools to improve the culture of the organization’s summer day camp. As staff became more comfortable using Six Sigma, project work became more organized and data-driven, and the project team exceeded its first-year goals. 

Achieving Customer Specifications through Process Improvement Using Six Sigma (PDF) – April 2015
The NutriSoil Company in Portugal, a small and medium-sized enterprise (SME), sells fertilizer in bags. The company has had problems with its filling process due to excess weight of the bags. Results show that by implementing Six Sigma combined with the 5S program, NutriSoil achieved an improvement in its Cpk index for this process, which increased consumer satisfaction and a highly significant cost savings. This resulted in increased competitiveness.

Driving Business Impact for Key Customers (PDF) – February 2015
This article discusses how lean and Six Sigma approaches were used for process improvement by CMITS, a business group within Genpact, a business consulting firm. CMITS focuses on information technology (IT) and IT-managed projects. All of 2012 was spent building lean and Six Sigma within CMITS and introducing Six Sigma tools for process improvement.

Let It Flow(PDF) – February 2015
Thomas Jefferson University Hospitals in Philadelphia has a large volume of inpatient and outpatient surgical volume flowing through its many operating rooms. The operating room is a setting abundant with opportunities for improvement. System inefficiencies can lead to sub-optimization of operating room use, thereby decreasing revenue generation. In 2010, the department underwent a strategic plan overview to identify opportunities to streamline and improve operational processes.

Mega Pack Line Blow-Up: DMAIC Roadmap Leads Boston Scientific Heredia to Reengineer Packaging Lines – December 2014
Corporate rates of improvement at Boston Scientific represent a yearly challenge and opportunity to improve and exceed different operation indicators such as service and efficiency, safety, quality, and cost within the company. A DMAIC roadmap provides a standardized and recognized set of tools to be used as methodology during part of the project implementation, based on a lean manufacturing point of view. Core team members and product builders within the Amplatz Super Stiff™ Guidewires area worked together to improve efficiency, increase safety, and save money using a DMAIC roadmap.

Rock Solid: Combining lean, Six Sigma and theory of constraints creates a process improvement powerhouse – December 2014
The 6TOC improvement method employs elements of Six Sigma, lean and the theory of constraints (TOC) to zero in on process bottlenecks and eliminate waste and variation. A 10-step implementation plan based on Eliyahu Goldratt’s chain project management process and Joseph M. Juran’s management principles can help any industry implement 6TOC.

Six Sigma Optimization of Mystery Shopping – September 2014
Mystery shopping (MS) can be a very valuable exercise for studying and evaluating service delivery performance within the banking industry. Using Six Sigma tools and hypothetical data, this case study tests the approach and results to gauge poor service from excellent service delivery. The MS approach is highly applicable as a balanced scorecard parameter to measure delivery within service centers.

Do you have Six Sigma results to share? Let ASQ publish your success story.

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