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See Benchmark in Action

Browse real-world caselets that showcase how Benchmark Six Sigma has helped organisations solve critical problems, reduce costs, boost efficiency, and drive results.

Use the filters below to explore by industry or solution area. Each caselet highlights a challenge, our approach, and the impact delivered.

🔍 Select a category to explore what’s possible for your organisation.

Caselet Filters

  • Operations > Cost Reduction

    Operations Cost Reduction Project

    A cost reduction project was undertaken at a leading alumina manufacturer in their Orissa plant. Project focused on reducing the annual specific coal consumption (coal consumed per unit of alumina produced). The scope included optimizing the power plant output along with studying the leakages in the production plant. Solutions implemented included upgrades to energy-efficient motors, installation of sheds in coal storage area to prevent coal wetting, installation of variable frequency drives on pumps and fans, optimization of process parameters, implementation of waste heat recovery systems, improved insulation, and replacement of conventional lighting with LEDs. The project was able to reduce the specific coal consumption from 0.352 to 0.327 T/T leading to annual cost reduction of INR 35 Cr.

    Process Manufacturing > Additional Process Manufacturing

  • Maintenance > Reliability

    Enhancing Equipment Reliability

    A large tile manufacturing factory experienced frequent machine failures, leading to inconsistent production output, variation in tile quality and high repair expenses totaling about INR 5 lacs annually. To enhance reliability, a project was done to adopt Reliability-Centered Maintenance (RCM) practices. Project integrated predictive maintenance technologies, such as vibration analysis and thermal imaging, and established a routine inspection protocol. These measures identified potential failures before they occurred, reducing unplanned downtime by 40% and lowering repair costs by INR 3 lacs each year. The project also extended the lifespan of critical equipment, resulting in improved reliability.

    Process Manufacturing > Additional Process Manufacturing

  • Lean HR > HR Analytics

    Benchmarking Compensation for Retention

    An HR analytics project was carried out to do a benchmarking study for the Compensation and Benefit program. The organization faced challenges with retaining top talent due to non-competitive compensation and benefits, resulting in a high turnover rate of 18% at Senior Manager and above level and increased recruitment costs of INR 54 lacs annually. The team benchmarked salaries and benefits against industry standards, implemented equitable pay structures, and enhanced the benefits package by adding performance-based incentives, ESOPs and flexible work options. Additionally, the team introduced transparent communication strategies to ensure employees understood their compensation benefits. As a result, the compensation packages became industry-aligned, reducing turnover to 10% and improving employee satisfaction scores by 20%. This alignment not only enhanced employee retention but also positioned the company as a competitive employer in the market.

    Process Manufacturing > Additional Process Manufacturing