Case Studies

Methodology Industry
Project Area
Focus Key Tools Results
Six Sigma Lean
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Large Equipment Manufacturer
Invoice & Collection Process
Reduce Days sales outstanding by 4 days, minimum, in order to increase cash flow Process Map, Cause and Effect, FMEA, Multivariable Analysis, Control Plan With in 5 months, reduced days sales outstanding across 52 sales offices from 52.2 days to 48 days,
> $9.5 million in increased cash flow
Six Sigma Lean
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Pharmaceutical
Chemical formulation process
Reduce amount of key expensive chemical in reaction without
increasing amount of un-reacted agent, in order to reduce cost
Design of Experiments, Multiple Response Optimization Reduced amount of chemical required:
 > £100,000 / year savings
Six Sigma Lean
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Automotive Supplier
Multi-cavity Mold
Reduce variation in key dimension
on part in order to maintain (not lose) business
Process Mapping, Prioritization matrix, FMEA,
Measurement Systems Analysis, Design of Experiments
Reduced variation of key dimension 70%:
Selected as key supplier
Six Sigma Lean
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High Volume Equipment Manufacturer
Manufacturing Extrusion and Forming  Process
Reduce variation in key dimension in order to
response to  customer rejection  of 700,000 units
Process Map, Cause and Effect, FMEA, Multivariable
Analysis, Control Plan
Reduced variation of key dimension by 75%
Maintained key customer contract, doubled sales
Business Process Management Systems
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Electronic defense
Human Resources
  Customer and needs identification, Value Chain
Mapping, Prioritization Matrix,  Value Profile Survey, Process
Mapping, Gap Analysis
Identified cost gap of
> $1.2 million/ year
Prioritized projects to address and close gap
Design Six Sigma: Technical Product and Process
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Electronics
Design, Test and assembly
Decrease reject rate of component
by a factor of 10 in order to reduce rework, scrap, inventory
Measurement Systems Analysis,  Statistical
Graphical Analysis, Statistical Tolerancing
Sourced new supplier
>$700,000Savings/ year
Design Six Sigma: Service and Process
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Insurance
Administrative Process
Increase set up accuracy from 83%
to 99%, in order to reduce rework
Customer interviews, KJ, QFD, Process Mapping,
FMEA, Statistical Graphical Analysis
Decreased rework and non value add:
>$150,00 savings Increased customer satisfaction
>$400,000increased revenue
Innovation Six Sigma
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Medical Nutritional Products

Health Care Market
Identify key opportunities in the
growing health care market
Opportunity ID,  Outcome analysis, Customer
Value Chain, Perceived  Quality Survey
Identified an untapped opportunity, created
new market

Business sold to major pharmaceutical firm