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Lean Six Sigma Project Examples | 17 Full Case Studies

Ready to begin your first Lean Six Sigma project? Looking for examples for inspiration or reference to get you started? Here are some project storyboards from different industries and from home. Remember, Lean Six Sigma can help you with more than just work!

• Reducing Underwriting Resubmits by Over 20%  

Governments

• A Call to Change: Pioneering Lean Six Sigma at Los Angeles County  
• Can Lean Six Sigma Be Applied in County Government?  
• How the City of San Antonio Increased Payments for Street Maintenance Using Lean Six Sigma  
• Reducing Bid Tab Creation Cycle Time by 22%  
• Reducing Cycle Time for Natural Disaster Response by 50%  

Manufacturing

• Increasing First Run Parts From 60% to 90% With Lean Six Sigma  
• Reducing Bent/Scratched/Damaged (BSD) Scrap for Building Envelopes  
• Reducing Lead Time in Customer Replacement Part Orders by 41%  
• Reducing Learning Curve Ramp for Temp Employees by 2 Weeks  
• Reducing Purchase Order Lead Time by 33% Using Lean Six Sigma  
• Herding Cats Using Lean Six Sigma: How to Plan for and Manage the Chaos of Parallel Processes  
• Lean Six Sigma Increases Daily Meat Production by 25%  
• Lean Six Sigma Helps Feed People In Need 45% Faster  
• Accelerating Lean Productivity With Immersive Collaboration  
• Reducing Incorrect Router Installations by 60% for Call One  
• Reducing Software Bug Fix Lead Time From 25 to 15 Days  

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Six Sigma Case Study: Everything You Need to Know

Explore the field of Six Sigma Case Studies in our comprehensive blog. From defining the methodology to real-world applications, our 'Six Sigma Case Study: Everything You Need to Know' blog sheds light on this powerful problem-solving tool. Uncover success stories and learn how Six Sigma can drive efficiency and quality improvements in various industries.

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By analysing such case studies, one can gain insights into the successful application of Six Sigma in various industries and understand its impact on process improvement. Read this blog on Six Sigma Case Study to learn how real-world businesses have achieved remarkable process improvement and cost savings. 

Table of Contents  

1) Understanding Six Sigma Methodology 

2) Six Sigma Case Study 

a) Improving customer service 

b) Improving delivery efficiency 

3) Conclusion 

Understanding Six Sigma Methodology

By applying statistical analysis and data-driven decision-making, Six Sigma helps organisations identify the root cause of problems and implement effective solutions. It emphasises the importance of process standardisation, continuous improvement, and customer satisfaction. With its focus on rigorous measurement and analysis, Six Sigma enables organisations to drive efficiency, reduce waste, and deliver exceptional products and services. The methodology follows a step-by-step process called Define, Measure, Analyse, Improve, and Control (DMAIC). These five phases are briefly explained below: 

a) Define: The project goals and customer requirements are clearly defined in this phase.  

b) Measure: In this phase, data is collected to understand the process's current state and identify improvement areas.  

c) Analyse: This phase focuses on analysing data to determine the root cause of defects or variations.  

d) Improve: This phase involves implementing solutions and making necessary changes to eliminate the identified issues.  

Six Sigma Case Study  

In this section we discuss two Six Sigma Case Study that will help you understand and use it better.  

Case Study 1: Improving customer service  

This Six Sigma Case Study will focus on a telecommunications company facing significant customer service challenges. The issues included long wait times, frequent call transfers, unresolved issues, and many more. The company decided to apply Six Sigma methodologies to enhance customer satisfaction.  

a) Define phase: Using the DMAIC approach, the team began by defining the problem: long wait times and inefficient call handling. They set a goal to reduce average wait time and increase first-call resolution rates.  

b) Measure phase: In this phase, data was collected to analyse call volume, wait times, and reasons for call transfers. This helped identify bottlenecks and areas for improvement.  

c) Analyse phase: During this phase, the team discovered that inadequate training and complex call routing were key contributors to the problems. They also found that certain product issues required better resolution protocols.  

d) Improve phase: In this phase, targeted solutions were introduced and implemented to address these issues. The team revamped the training program, ensuring agents were well-trained and equipped to handle customer inquiries. They simplified call routing and introduced automated prompts for quicker issue resolution.  

e) Control phase: Finally, monitoring systems were established in the control phase to track key metrics and ensure sustained improvements. Regular feedback loops were implemented to identify emerging challenges and make necessary adjustments.  

The results were exceptional. Average wait times were reduced by 40%, and first-call resolution rates increased by 25%. Customer satisfaction scores improved significantly, leading to increased loyalty and positive word-of-mouth.  

This Six Sigma Case Study highlights how Six Sigma methodologies can drive transformative improvements in customer service. By focusing on data analysis, process optimisation, and continuous monitoring, organisations can achieve outstanding outcomes and deliver exceptional customer experiences. 

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Case Study 2: Improving delivery efficiency

a) Define phase: The business used the Voice of the Customer (VoC) tool to understand customer needs and expectations. They identified prompt delivery, correct product selection, and a knowledgeable distribution team as crucial customer requirements. 

b) Measure phase: The team collected data to evaluate the problem of slow delivery. They discovered that their Order Fulfillment Cycle Time (OFCT) was 46% longer than competitors, leading to customer dissatisfaction.  

c) Analyse phase: The team brainstormed potential causes of slow delivery, including accuracy of sales plans, buffer stock issues, vendor delivery performance, and manufacturing schedule delays. They conducted a regression analysis, revealing that inadequate buffer stock for high-demand products was the main issue affecting delivery efficiency.  

d) Improve phase: The distributor implemented a monthly demand review to ensure that in-demand products are readily available. They emphasised ordering and providing customers with the specific products they desired.  

e) Control phase: The team developed plans to monitor sales of the top 20% of bestselling products, avoiding over or under-supply situations. They conducted annual reviews to identify any changes in demand and proactively adjust product offerings.  

By applying Six Sigma Principles , the plumbing product distributor significantly improved its delivery efficiency, addressing the root cause of customer dissatisfaction. Prompt action, data-driven decision-making, and ongoing monitoring allowed them to meet customer expectations, enhance its reputation, and maintain a competitive edge in the industry. This case demonstrates the power of Lean Six Sigma in driving operational excellence and customer-centric improvements. 

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Conclusion  

We hope this blog gives you enough insights into the Six Sigma Case Study. This blog showcased the effectiveness of its methodology in driving transformative improvements. By applying DMAIC and using customer insights and data analysis, organisations have successfully resolved delivery inefficiencies, improving customer satisfaction and operational performance. The blog highlights how Six Sigma can be a powerful framework for organisations seeking excellence and exceptional value. 

Learn the six-sigma methodology to achieve business objectives with our Six Sigma Certification Training today!  

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Top Six Sigma Case Study 2024

Home Blog Quality Top Six Sigma Case Study 2024

Six Sigma is an array of methods and resources for enhancing corporate operations. When Bill Smith was an engineer at Motorola, he introduced it in 1986 to find and eliminate mistakes and defects, reduce variance, and improve quality and efficiency. Six Sigma was first used in manufacturing as a quality control tool. When long-term defect levels are less than 3.4 defects per million opportunities ( DPMO ), Six Sigma quality is reached.

Six Sigma case study   offers a glimpse into how various companies have harnessed the five distinct phases: defining, measuring, analyzing, improving, and controlling, principles of Six Sigma to overcome challenges, streamline processes, and improve across diverse industries.

What Are Six Sigma Case Studies, and Why Are They Important?

Six Sigma case studies examples   show how Six Sigma techniques have been used in businesses to solve issues or enhance operations. For practitioners and companies pondering enforcing Six Sigma concepts, these case studies are an invaluable resource to learn the advantages and efficacy of Six Sigma adoption.

Here are the reasons why six sigma case study is important:

Success Illustration: Case studies demonstrate how Six Sigma projects generate tangible advantages like better productivity, fewer defects, and more customer satisfaction while providing unambiguous evidence of their efficacy.

Learning Opportunities:  They deliver vital insights to use Six Sigma tools and processes realistically and allow others to learn from successful approaches and avoid common errors.

ROI Demonstration:  Case studies provide quantitative data to show the return on investment from Six Sigma projects, which helps justify resources and get support for future initiatives.

Promoting Adoption:  They cultivate a continuous improvement culture and show how Six Sigma concepts can be used in different situations and sectors, which encourages other businesses to embrace the methodology.

Become a Six Sigma Certified Professional and lead process improvement teams to success. Learn how to streamline processes and drive organizational growth in any industry. Join our Lean 6 Sigma training courses and transform your career trajectory with valuable skills and industry recognition.

Six Sigma Case Studies

Let us discuss some real-world case study on six sigma   examples of successful Six Sigma undertakings through case studies:

1. Six Sigma Success: Catalent Pharma Solutions

Do you know how Six Sigma techniques turned things around for Catalent Pharma Solutions?

Six Sigma methodologies, initially presented by Motorola in 1986 and prominently used by General Electric during CEO Jack Welch's leadership, are essential for enhancing customer contentment via defect minimization. Catalent Pharma Solutions, a top pharmaceutical development business, employed Six Sigma to address high mistake rates in its Zydis product line. By applying statistical analysis and automation, training employees to various belt levels, and implementing Six Sigma procedures, Catalent was able to maintain product batches and boost production. This case study illustrates how Six Sigma approaches are beneficial for businesses across all industries as they can improve processes, prevent losses, and aid in cost reduction.

2. TDLR's Record Management: A Six Sigma Success Story

The Texas Department of Licensing and Regulation (TDLR) faced escalating costs due to the storage of records, prompting a Six Sigma initiative led by Alaric Robertson. By implementing Six Sigma methodologies, process mapping, and systematic review, TDLR successfully reduced storage costs and streamlined record management processes. With a team effort and strategic changes, TDLR has achieved significant cost savings and improved efficiency. The project also led to the establishment of a robust records management department within TDLR.

3. Six Sigma Environmental Success: Baxter Manufacturing

Baxter Manufacturing utilized Six Sigma principles to enhance its environmental performance and aim for greater efficiency. Through the implementation of Lean manufacturing and accurate data collection, Baxter reduced waste generation while doubling revenue and maintaining waste levels. With a cross-functional team trained in Six Sigma, the company achieved significant water and cost savings without major investments in technology. It led to promotions for team leaders and showcased the effectiveness of Six Sigma in improving environmental sustainability.

4. Aerospace Manufacturer Boosts Efficiency With Six Sigma

Have you heard about how Six Sigma principles transformed an aerospace parts manufacturer? Here is the 6 Sigma case study   for aerospace parts manufacturer

A small aerospace parts manufacturer used Six Sigma to cut machining cycle time, reducing costs. Key engineers obtained Six Sigma certification and led the project, involving management and operators. Using DMAIC, they analyzed data, identified root causes, and implemented lean solutions. The process yielded a 46% reduction in cycle time and an 80% decrease in variation, enhanced productivity and profitability. The case highlights how Six Sigma principles can benefit businesses of all sizes and emphasizes the importance of training for successful implementation.

Enroll in the  Lean Six Sigma Green Belt certification online training to advance your career! Gain expertise in process improvement and organizational transformation with expert-led training and real-world case studies. Start now to become a certified professional in quality management.

5. Ford Motors: Driving Success

This is a   case study on Six Sigma  i ncorporated by Ford Motors to streamline processes, improve quality, significantly reduce costs, and reduce environmental impact. Initially met with skepticism, Ford's implementation overcame challenges, achieving remarkable results: $2.19 billion in waste reduction, $1 billion in savings, and a five-point increase in customer satisfaction. Ford's Consumer-driven Six Sigma initiative set a benchmark in the automotive industry and proved the efficacy of data-driven problem-solving. Despite obstacles, Ford's Six Sigma exemplifies transformative success in process improvement and customer satisfaction enhancement.

6. 3M's Pollution Prevention Six Sigma Success

Have you checked out how 3M tackled pollution with Six Sigma? It's pretty remarkable. 3M leveraged Six Sigma to pioneer pollution prevention, saving $1 billion and averting 2.6 million pounds of pollutants over 31 years. With 55,000 employees trained and 45,000 Lean Six Sigma projects completed, they focused on waste reduction and energy efficiency. Results included a 61% decrease in volatile air emissions and a 64% reduction in EPA Toxic Release Inventory. Surpassing goals, they doubled Pollution Prevention Pays projects and showcased Six Sigma's prowess in cost-saving measures.

7. Microsoft Sigma Story Lean Six Sigma

By using Lean Six Sigma case studies, Microsoft increased customer interactions and profitability through waste removal and process optimization. They concentrated on improving the quality of the current process and reducing problems by utilizing the DMAIC technique. Eight areas were the focus of waste elimination: motion, inventory, non-value-added procedures, waiting periods, overproduction, defects, and underutilized staff talent. Microsoft streamlined processes and encouraged innovation, which allowed them to maintain productivity and client satisfaction even as technology changed.

8. Xerox's Lean Six Sigma Success Story Six Sigma

It is another important case study of the Six Sigma project. When Xerox implemented Lean Six Sigma in 2003, the organization underwent a significant transformation. They reduced variance and eliminated waste as they painstakingly optimized internal operations. It improved their operational effectiveness and raised the caliber of their goods and services. Through extensive training programs for staff members, Xerox enabled its employees to spearhead projects aimed at improving different departments and functions. The organization saw significant improvements in customer satisfaction and service performance.

9. A Green Belt Project Six Sigma Case Study

It is one of the best examples of a Six Sigma case study. Anne Cesarone's Green Belt project successfully reduced router configuration time by 16 minutes, a remarkable 55% improvement. Anne maintained router inventory, made improvements to documentation and configuration files, and started router requests sooner by resolving last-minute requests and setup mistakes. The initiative resulted in less router programming time from 29 to 13 minutes, an increase in router order lead time of 11 days, and a 60% drop in incorrect configurations. These raised customer happiness and increased operational effectiveness while proving the benefits of process improvement initiatives.

10. Improving Street Maintenance Payments with Lean Six Sigma

Jessica Shirley-Saenz, a Black Belt at the City of San Antonio, used Lean Six Sigma to address delays in street maintenance payments Lean Six Sigma case study examples. Contractors were experiencing extended payment times, risking project delays and city infrastructure integrity. Root causes included payment rejections and delayed invoicing. By implementing quantity tolerance thresholds, centralizing documentation processes, and updating payment workflows, monthly payment requests increased from 97 to 116. Rejected payments decreased from 17 to 12, reducing the rejection percentage from 58% to 42%, saving $6.6 million.

 Six Sigma's effectiveness spans industries, from healthcare to technology. Case studies demonstrate its ability to optimize processes and improve outcomes. From healthcare facilities streamlining patient care to tech companies enhancing software development, Six Sigma offers adaptable solutions for diverse challenges. These real-world examples illustrate how its methodologies drive efficiency, quality, and customer satisfaction. Professionals can learn valuable lessons from using Six Sigma in healthcare studies, identify strategies to overcome obstacles and facilitate continuous improvement. Organizations can emulate best practices and implement similar initiatives to achieve measurable results by studying successful implementations.

Ready to enhance your skills and advance your career with Six Sigma certification? Join our comprehensive KnowledgeHut's best lean Six Sigma courses to master Six Sigma principles and methodologies. Become a sought-after professional in IT, Manufacturing, Healthcare, Finance, and more industries. Enroll now to accelerate your career growth!

Frequently Asked Questions (FAQs)

Six Sigma case studies are available in various formats and places, such as books, academic journals, professional publications, and Internet sites. Many companies that have effectively adopted Six Sigma publish their case studies on their websites or at industry exhibitions and conferences.

Six Sigma case studies provide insightful information on how businesses have addressed certain issues, enhanced procedures, and produced noticeable outcomes. Professionals gain knowledge about best practices, prevalent errors to avoid, and creative problem-solving methods in several industries and circumstances.

Professionals can share their Six Sigma case studies through industry forums, professional networking platforms, blogs, and social media. They can submit their case studies to publications or at conferences and workshops to reach a wider audience within the Six Sigma community.

Shivender Sharma

Shivendra Sharma, an accomplished author of the international bestseller 'Being Yogi,' is a multifaceted professional. With an MBA in HR and a Lean Six Sigma Master Black Belt, he boasts 15 years of experience in business and digital transformation, strategy consulting, and process improvement. As a member of the Technical Committee of the International Association of Six Sigma Certification (IASSC), he has led multi-million dollar savings through organization-wide transformation projects. Shivendra's expertise lies in deploying Lean and Six Sigma tools across global stakeholders in EMEA, North America, and APAC, achieving remarkable business results. 

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Lean Six Sigma PM Briefcase

Lean Six Sigma Case Studies for PMOs, Program Managers, and LSS Practitioners

The studies in this section demonstrate the application of several important Lean Six Sigma principles, techniques, and methods to solve problems in real business situations.

The lean six sigma case studies focus on product engineering , manufacturing operations , and cross-functional programs .

Product Upgrade Pre-launch Out-of-Box Failure (OOBF)

Explore the use of these techniques:     Why 5 Times     Failure Modes, Effects, and Criticality Analysis (FMECA)     Process Flow and Value Stream Mapping

Engineering Case Study

Engineering projects encompass:.

    New product development     On-market product enhancements     Design correction for field experience problems

Production Six Sigma Quality Improvement Project

Explore the use of these techniques:     Problem Definition Statement     Fishbone Root Cause Analysis     Turning Data into Actionable Information     Corrective Action / Preventive Action (CA/PA)     Statistical Process Control (SPC)

Production Operations Case Study

Production operations projects encompass:.

    Expansion, quality improvement, cost reduction     Automating labor-intensive processes     Optimizing internal and outsourced production

Rapid Response Problem-solving on a Customer's Field Return

Explore the use of these techniques:     8D Problem-solving Framework     Fishbone Root Cause Analysis     Implement Corrective Action / Preventive Action (CA/PA)

Cross-Functional Program Case Study

Cross-functional program projects encompass:.

    Product service actions and recalls     Root cause analysis and CA/PA     Market and customer responsiveness     General management problem-solving   

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Lean Six Sigma Case Studies

Welcome to the Lean Six Sigma Academy’s Case Studies section! Here, you will find a collection of real-world examples of how companies have successfully implemented the Lean Six Sigma methodology to improve their business operations. Each case study includes an overview of the business challenge that was faced, the approach that was taken, the results that were achieved and feedback from the client on their experience. These case studies showcase the wide range of industries and organizations that have benefited from Lean Six Sigma, and serve as inspiration and guidance for those looking to implement the methodology in their own business. 

OE Partners

Orrcon Steel

The toyota production system.

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Real-Life Examples of Six Sigma Implementation – Six Sigma Examples/ Use Cases

Six Sigma is a creative and flexible  series of methodologies aimed at improving organizational process quality and effectiveness. This blog on Six Sigma examples will explain a few use cases of Six Sigma methodology. Business today requires companies to be operational at maximum efficiency and effectiveness. The competitive markets mean everyone is looking to distinguish themselves and offer better products and services. A sustainable way to introduce better business practices is by changing your approach fundamentally. 

Companies are built to achieve corporate goals. The methods to achieve them are plenty and streamlined by management for incorporation. The concepts of optimization, minimizing waste, and maximizing productivity are strongly incorporated into the foundation of Lean and Six Sigma principles. 

These business models are conceptual and can be adapted to any industry or business environment. All you need is a guided professional and a willingness to convert your better business practices into the best possible. In this article, let us explore some Six Sigma examples and success stories.

What is Six Sigma?

The definition of Six Sigma has been under much debate. It can be broadly classified into four concepts:

A Philosophy  – Six Sigma is a school of thought that views workflows and activities as processes that can be expounded, quantified, analyzed, bettered, and monitored. It states an input is required to produce an output. Therefore, exercising control over the input gives you a firm hand in managing output. It is sometimes expressed in the equation  y=f(x)  where  x  stands for the input and  y  for the output. 

A Set of Tools –  Six Sigma comprises controls such as qualitative techniques and quantitative tools used to improve business capabilities internally. Six Sigma tools include SPC (statistical process control), FMEA (failure mode and effects analysis), and control charts. Professionals who deal with Six Sigma explain that tools are continually evolving and are not set in stone. 

A Methodology –  Six Sigma is considered to be a derivative of the DMAIC approach . DMAIC is a data-centric improvement method that operates cyclically. It revolves around Defining, Measuring, Analyzing, Improving, and Controlling. This principle drives Six Sigma users to begin by understanding the existing problem and implementing long term solutions. 

A Metric –  When assessing Six Sigma as a metric, it is defined as 3.4 defects per million opportunities.

Six Sigma, in its simplest form, reduces the possibility of variation in production. The objective is to have a firm grasp on the production process. Lean Six Sigma is a term often associated with Six Sigma. Lean methods are used to minimize wastage during production; this includes time and resources spent on processes that do not directly contribute to better output from activities. Lean Six Sigma is a philosophy that brings together waste minimization and production optimization. It improves customer satisfaction by removing unnecessary processes and waste, creating better workflows, faster output, and possibly a competitive advantage. To attest to the importance of Six Sigma, in the next section of this article, let us explore some Six Sigma examples.

Implementing Six Sigma 

Six Sigma can be implemented in a number of strategies, however there are two baseline options provided to all organizations looking to make the transition;

Introducing Six Sigma Training

Organizations can introduce a fundamental revamp across the organization through a Six Sigma program. Expose employees to better practices and conditioning by introducing the fundamentals and allowing a professional to understand what Six Sigma is and what it helps with. It is important to note that it is mostly an information transfer that happens during Six Sigma training . It is up to the business to adopt the methods to the organization and its practices. 

Introducing Six Sigma Infrastructure 

Creating a Six Sigma infrastructure can be quickly moved along by introducing certified professionals into your organization. Often called “Black Belts”, they move into your business for a period of four weeks to four months and begin teaching your business how to adapt the strategies to your activities. Creating the infrastructure creates a firm guideline to make changes to operations and corporate culture. 

Now let us look into some interesting Six Sigma examples and success stories.

Six Sigma Examples

There are several organizations across various industries that have adopted Six Sigma practices to great success . High profile clients include;

General Electric

The American multinational was struggling to improve overall product quality and service even with the best professionals onboarded. After running a six sigma method trial, the company was able to introduce better-streamlining measures into product assurance. As a result, revenue increased. 

This Indian based technology behemoth was the industry frontrunner for consumer goods. However, their customer service was less than satisfactory. Enter Six Sigma. Over time the methods were used to neutralize threats and create a better experience for clients. 

We all know and love the technology giant that gave us Windows and Office. A contributing factor to the success behind their service and products is Six Sigma. The industry leader has made it no secret that Six Sigma methods have enabled better back-end processes and, as a result, better user experience. It acts as a case in point for companies looking to transition into Six Sigma practices. 

The telecommunications company was one of the first to implement six sigma methods. As a trial, the company implemented Six Sigma to assess the impact on improving product quality and streamlining the transition between services to revenue. The positive results created better company-wide performance and permanent incorporation. 

Boeing   Airlines

One of the world’s largest aerospace companies was having issues with air fans within the engines. Unable to pinpoint the exact problem, a group of experts were called in to investigate. They deduced the problem stemmed from FOD (foreign object damage). Upon more in-depth inspection using Six Sigma methods , they could trace the problem to a more fundamental manufacturing issue causing electrical issues along with the FOD. 

Practically, the application for six sigma methods can be seen across any organization attempting to create better output. Introducing better control measures for various parts of the production process helps produce desirable results. 

Final Thoughts

The beauty of Six Sigma methods lies in their ability to adapt to different environments. The increased efficiency and effectiveness are tangible in the success stories of industry giants implementing Six Sigma to success. Add to the real-life Six Sigma examples of by introducing skilled professionals or the Six Sigma infrastructure to your organization. 

The enterprises usually divide their workforce depending on the hierarchy to get their employees trained in different  Lean Six Sigma training programs  in Yellow Belt, Green Belt, Black Belt, Master Black Belt, and Six Sigma Champion. To get a better understanding of which Lean Six Sigma course benefits the most for you or the team, check out some of the popular courses below to get a comprehensive understanding of the same: 

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Six Sigma Case Study: KLM Royal Dutch Airlines

July 3rd, 2017

Since the deregulation of airlines in the United States in the 1970’s, we have witnessed countless mergers, take-overs, and joint ventures form. From TWA and American Airlines to United and Continental, airlines seem to continuously fold into one another. However, one airline continues to be a true inspiration of endurance and stability. Across the pond, we will analyze the success of KLM Royal Dutch Airlines. Learn how the airline uses Six Sigma principles to continue its famous title as the “World’s Oldest Airline”.

Introduction to KLM

KLM Royal Dutch Airlines is the national airline for The Netherlands. Beginning operations in 1919, KLM founded itself in the province of Noord-Holland near the city of Amsterdam. At the time, Amsterdam’s Schiphol Airport was a fraction of the size it is today. Likewise, the airline’s focus was on transporting passengers and freight to nearby cities, such as Brussels, London, and Paris. However, it wasn’t until after World War 2 did the airline really take off.

Hub-Focused Business Model

When you think of airlines, you first thought is, of course, the airplanes. Yet, for KLM, it’s the airport. Amsterdam Schiphol Airport is now one of the largest and busiest airports in the world thanks to the guidance of KLM’s business model. Most airlines in the United States operate numerous hubs, fly to hundreds of destinations, and have upwards of 1,000 airplanes. KLM, on the other hand, focuses on one specific hub; Amsterdam. By maintaining one hub city, the airline operates what is known as a hub-spoke model. That is, instead of operating numerous flights from various cities, most all flights originate and depart from Amsterdam. This business model follows the idea of constant improvements towards efficiency which Six Sigma promotes .

Revolutionary Aircraft

Next, instead of focusing strictly on passengers, KLM looks towards cargo. While all airlines to an extent ship cargo to their destinations, most do not offer separate cargo services. The Royal Dutch Airline, on the other hand, took this opportunity to do so. In order to offer affordable and profitable cargo services, KLM revised their long-haul operations with the Boeing 747-400 combi. This modified Boeing aircraft uses nearly half the fuselage to ship cargo. Typically, all cargo rides underneath the main deck of aircraft. However, with the 747-400 combi, airlines can store more, larger cargo near the back of the airplane. This decision to invest in a new aircraft follows the DMAIC process . The airline wants to ship more cargo but does not have the space to do so. What is the most economic decision? For KLM, it’s to invest in a new aircraft that focuses on both cargo and passengers.

Although there are numerous variables that have led to the success of KLM, all revert to the principles of Six Sigma. When you focus on providing a superior service that works within your limitations, your organization can flourish and grow naturally. As the Dutch national airline continues to operate, it will face new challenges with each achievement. However, by sticking to the methods of Six Sigma, KLM can continue to be the oldest airline in the world!

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Case Study: Six Sigma for Small Business

Six Sigma has proven to work for huge companies like Motorola and GE, which accumulate a lot of waste and redundancy because of their sheer size. But what about smaller organizations? What about local businesses?

What about your company?

Is Six Sigma worthwhile for smaller institutions who don’t have hundred-man teams, or thousand-step processes?

Well, in October 2017, three people asked that same question. They conducted a study, and they published their findings in the Advances of Mechanic Engineering section of  SAGE Journals .

Two of the authors – Murilo Riyuzo Vendrame Takao and Iris Bento da Silva – work in mechanical engineering at the University of São Paulo, in São Carlos Brazil. The other author, Jason Woldt, teaches management classes at the University of Wisconsin-Platteville. They put their heads together to create a comprehensive study on the effects of Six Sigma, as it applied to one specific small-to-medium-sized enterprise…

A plumbing product distribution business.

Spoilers: Six Sigma works.

It has worked for huge businesses like General Electric, and it still works for small- and medium-sized enterprises (SMEs) like your neighborhood lemonade stand.

“This article uses a case study highlighting the implementation of Six Sigma methodology in a North American manufacturer of plumbing products (SME). Each step of the process is properly described, and the results are also presented,” the authors said.

“We conclude that it is possible to identify the improvements and benefits achieved by the implementation of the Six Sigma quality program in an SME environment.”

How did they reach this conclusion? What did they find?

The Six Sigma Difference

They discovered that Six Sigma is different from other quality management programs because of the structured application of its tools and procedures (and, specifically, how those tools integrate with the goals of an organization).

These tools are used to facilitate each step of DMAIC – a project development framework, and a tent-pole of Six Sigma. It stands for…

Define: Figure out the scope and importance of your project, identify the needs of your consumers, and then assemble the team responsible for the project’s execution.

Measure: Pinpoint the problem you’re trying to solve, gather all the data you need, determine priority problems, and establish goals.

Analyze: Discover the cause of the priority problems and figure out where the problems start.

Improve: Propose, evaluate, and implement solutions to priority problems.

Control: Maintain the scope of the long-term goal, monitor performance, and take corrective action to keep on track.

Video: What is Six Sigma?

Levels of Six Sigma

DMAIC works across all levels and scopes of Six Sigma projects and practitioners. And for your reference, Six Sigma features a hierarchy of six components:

White and Yellow Belts: those practitioners who are trained in the basic tools of Six Sigma.

Green Belts: those practitioners dedicated to improvements within a project.

Black Belts: those practitioners who lead projects and train staff.

Master Black Belts: those practitioners who connect the general management of Six Sigma projects to the people responsible for the improvement projects.

Champions: members of the executive committee.

Sponsors: those who promote and define the guidelines for Six Sigma implementation.

The Case Study

There are dozens of tools that can be used during DMAIC, and the research dives into their case study to show a few tools in action.

The case study covers a period of about 18 months, following (as previously mentioned) a plumbing product distributor. The company wasn’t being well-received by its customers, and it endeavored to find out why.

Enter the Define phase. One of the tools they used was called voice of the customer (VoC), which defines the needs and requirements of your customer base. It’s a very important tool for a company that’s not getting a lot of positive reviews. For the case study, VoC showed that customers expected prompt delivery, correct product selection, and a knowledgeable distribution team.

So, with their problem discovered, they ventured into the Analyze phase, where they worked to answer one question – why was their delivery so slow, compared to their competitors? They brainstormed causes, and came up with four potential causes: (1) the accuracy of the sales plans, (2) safety stock issues, (3) vendor delivery performance, and (4) falling behind the manufacturing schedule. They conducted regression analysis on all potential causes, to see which one would cause the most trouble. And they found it. After creating a Pareto diagram , they realized that 74% of their sales came from only 21% of their products – and there wasn’t enough safety stock to get those in-demand products to all the customers who wanted them.

That led to the Improve phase, where they aimed to solve the problem. They started by implementing a monthly demand review, to make sure the in-demand products stayed in-demand, and it wasn’t a one-time fluke. The second measure was to actually order and provide the customers with the products they wanted.

The Control phase was simple. They wanted to make sure their solutions worked for as long as possible, so they created plans to monitor sales on their bestselling 21% of products (to make sure they weren’t exceeding or under-supplying demand). And every year, they’d review how well those products sold; if a product started following out of high demand, they could replace it with a product that was coming into high demand.

The Results

After 18 months with the plumbing product distributor, the researchers came to a confident conclusion.

“This case study illustrates that quality management and its tools should be increasingly adopted regardless of whether they are SMEs or large companies. Thus, in order to achieve competitiveness, the Six Sigma methodology should be much more applied in the SMEs, due to the interrelationship with the stakeholders and limited use of consultancies.”

Using Six Sigma principles , the company in the case study increased their annual sales by $248,034. They reduced delivery time by more than four full days.

The Takeaway

This research is another point in favor of process improvement methodologies. It doesn’t matter how big your company is, how many employees you have, or how much revenue you gross every year.

All. Companies. Have. Processes.

Whether you’re distributing plumbing supplies, making billion-dollar acquisitions, or selling lemonade on the street corner, Six Sigma is absolutely worth looking into.

How Utilizing the Full Six Sigma Process Helped Turn Wipro Into a Global IT Leader

Updated: April 22, 2023 by Lori Kinney

In the 1980s, Wipro made the leap from being primarily known as a vegetable oil company in India into the world of IT. In order to be a competitor in this industry on a global scale, Wipro would need to continually improve its performance as well as work smarter towards meeting the needs of its customers. It found the methodology to do so in Six Sigma.

When utilizing the Six Sigma methodology, many companies opt to tip their toe in, choosing just a couple of aspects of the methodology to see how it can improve their organization. Wipro, on the other hand, went all in. The organization implemented the full range of Six Sigma tools in its organization for its various service lines. This included incorporating DFSS , DCAM, and DSSP into the development of new processes. DMAIC and TQSS were utilized for the improvement of existing processes. For reengineering, CFP was used.

Wipro Had a Problem

Wipro was founded in 1945 and began its operations as a vegetable oil company. In the 1970s, the organization made its first moves towards expanding beyond this particular industry by manufacturing pneumatic and hydraulic cylinders. By 1979, operations had further expanded into consumer care products like baby care products and toiletries as well as into instruments used in healthcare.

With the economic reforms of India in the1980s, the organization found itself in a position where it could expand even further into another field. The company began putting its focus on IT and found unparalleled success in this endeavor on the domestic level. Wipro became the most successful information technology company in India. Wipro began looking towards the global marketplace. However, in order to be competitive on a global scale, it saw the need to improve the product performance of its telecom applications. A desire to make a dent in the United States would require the organization’s business operations to be in alignment with customer needs as well as a culture of continuous improvement. This would build customer trust and loyalty, as well as keep the company ahead of the global competition. The move towards a focus on quality led Wipro to Six Sigma.

The success of a corporate giant helps Wipro decide on the Six Sigma methodology

In 1995, Wipro was still a fairly small company that had begun its global outreach program with its software products and R & D services. Azim Premji, the chairman of Wipro, felt it necessary that the organization improve its quality practices if it was going to be a true global competitor. A joint venture with General Electric around the development and distribution of ultrasound devices helped Wipro see how General Electric conducted business. Premji saw General Electric’s major successes in its implementation of the Six Sigma process and knew that Wipro could greatly benefit from this methodology in its IT division as well.

The Initial Problems Wipro Ran Into Implementing Six Sigma

One hurdle that Wipro encountered in its early implementation of Six Sigma was getting the needed support from higher-level management. Applying the Six Sigma methodology with the kind of cohesiveness desired required a practical restructuring of the organization. This meant a great deal of training, building confidence in the program, and supplying the necessary infrastructure. Building up the company culture so that the Six Sigma process could succeed took a significant amount of time for Wipro.

Another issue was finding the right projects to put the organization’s initial focus on. Pilot projects would have to be launched in order to best learn the Six Sigma method and prove its success before the system could be fully integrated into Wipro’s operations. This meant selecting projects that had a high success probability and that would take a fairly short amount of time so that the proof of Six Sigma’s benefits could be shown quickly.

There was also the time needed to build a team that would be trained in the stages of Six Sigma. This training covered the five areas of DMAIC as well as a focus on increasing the satisfaction of the customer. Involved in this training were statistics, designing experiments, and benchmarking . With all of the work put into the training, Wipro was inspired to create its own consultancy.

The identification of resources required for individual projects also posed a challenge as they could vary greatly. Wipro developed a team of experts that could cover identification as well as determine the success of the various projects.

The Outcome Was Phenomenal

The benefits of adopting Six Sigma at Wipro were swift and clear. Software defects were reduced by a stunning 50%, software rework dropped from 12% to 5%, and productivity increased by 35%. In the hardware section of the business, installation failures dropped to 1% from a previous 4.5%. Data transfer also saw key improvements, such as the speed of transfer improving by 250%. The minimization of waste was also notably improved, as were company savings. This was attributed to changes that led to lower costs in development, maintenance, and schedule overruns. As far as global competition goes, Wipro was able to lower its field defects by 67% against the industry average.

All in all, over time, Wipro was able to reach a level where it could complete 93% of projects on time, become a global leader in IT, and deliver the kind of products and services that were seen as exemplary by its customer base.

6 Best Practices When Incorporating the Full Six Sigma Methodology Into Your Organization

While many companies may implement Six Sigma for a handful of projects or aspects of their business, Wipro used Six Sigma methods to completely transform how it operates. If there is a desire to take a similar approach at your organization, here are some best practices to consider:

1. Leadership onboarding

Having top leadership onboard for the switchover will be essential. They will need to be properly trained in order to appreciate and fully understand the benefits that Six Sigma offers to the organization. This training should cover roles and responsibilities, tools and techniques, and the necessity of top leadership to act as ambassadors for the methodology. By seeing the top-level belief in the system, there is a much greater likelihood of enthusiasm throughout the company.

2. Steering committee

Executive ownership of the methodology should also be demonstrated by the appointment of a committee that helps steer practices in the appropriate direction. This means that this committee will ensure that there is an alignment between organizational goals and Six Sigma-related projects. This committee will also ensure that the necessary resources required for the success of the projects are allocated and any potential roadblocks are fully removed.

3. Pilot projects

In order to demonstrate how adopting Six Sigma fully into your organization will yield exceptional benefits, launch a pilot program where a few smaller projects are focused on. These projects should be small enough to not cause executive concern, but significant enough that their success can be clearly determined. These projects should also have a defined and relatively short scope so that the outcome can be quickly shown and so that larger, long-term projects can be assessed.

4. Utilize all Six Sigma tools

Many organizations start and stop with DMAIC when incorporating Six Sigma into their organization. While this practice is hugely beneficial, Wipro opted to work the full Six Sigma methodology into how it operates. This meant finding pockets where such tools as DSSS, DCAM, DSSP, TQSS, and CFP could all serve vital functions.

5. Provide training at the floor level

Having the top brass trained in Six Sigma is vital, but it is also hugely important that all of your workers have the proper training in the fundamentals of this methodology. Wipro wound up having this training done internally and was so successful with it that the organization wound up starting its own consulting practice. If the resources are not there to have all of the training done internally, there are a wealth of resources available to outsource this type of training.

6. Prepare for a long-term commitment

While Wipro was able to see some major changes rather quickly from its adoption of the Six Sigma methodology, many of the full benefits took several years to manifest completely. Making such fundamental alterations to the way a business operates requires patience and steadfastness in order to see the full scope of the benefits that come with making such improvements. Make sure that your organization is well-prepared to weather the ups and downs that come with the short-term setbacks that may arise from such major change so that the long-term fruit can fully ripen.

Wipro’s Continued Success With Six Sigma

Wipro was the first company in India to adopt the Six Sigma methodology. Its incredible success has influenced many organizations throughout India to utilize Six Sigma as part of how they do business in a wide variety of industries. Today, Wipro still adopts many of the methods of Six Sigma as well as Lean. Six Sigma helped transform Wipro, and many years later, the organization is still reaping the rewards.

About the Author

Lori Kinney

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