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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
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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.
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Quality Control/ Quality Assurance > DOE
Optimizing Boiler Performance
A Design of Experiment sub-project was done in a food chemical processing company to optimize the boiler operations. The key issue was inefficient boiler operations leading to high variations and customer rejections in the end product. Project involved conducting a 2 level factorial experiment with factors like slurry feed rate, steam temperature, steam pressure and boiler output temperature. After analyzing the design, operating settings were optimized to get a consistent rate of evaporation, SOPs were updated and staff was trained on maintaining the optimized settings. The project was able to deliver an annual benefit of INR 45 lacs.
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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.
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Optimizing Packaging Line Maintenance
A project was done in a packaged food manufacturing plant. The key issue faced was frequent machine downtimes, costing approximately INR 50 lacs annually. To address this, the project team implemented a Predictive Maintenance System using IoT sensors on critical machinery. These sensors monitored real-time performance metrics and alerted the maintenance team of potential failures. The solution included integrating IoT platforms with existing ERP systems. As a result, unplanned downtimes reduced by 40%, saving INR 30 lacs annually and enhancing overall production efficiency. Additionally, the data collected enabled better resource planning, extended machinery lifespan and uninterrupted continuous manufacturing.
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Quality Control/ Quality Assurance > DOE
Integrating Quality by Design
A project was done in a pharmaceuticals company which was struggling with inconsistent product quality and lengthy development times due to insufficient process understanding. To address these issues, the project team adopted the Quality by Design (QbD) approach. This involved identifying critical quality attributes (CQAs) and critical process parameters (CPPs), conducting risk assessments, and utilizing design of experiments (DoE) to optimize manufacturing processes. By integrating quality considerations from the outset, the company built robustness into the product design and manufacturing process. As a result, the company achieved improved product quality, reduced batch failures by 30%, and shortened development time by 25%. Benefits included enhanced regulatory compliance, reduced time to market and cost savings from fewer rejected batches.
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Admin > Administrative Process Improvement
Streamlining Purchase Order Processing
A project was done to reduce the delays in processing the purchase orders. The average TAT was about 10 days. Key issues identified were non-standardized format of POs, multiple level of approvals, recon between multiple systems. Project included implementing a consolidated view of data from multiple sources of data, rationalizing the approval levels and standardizing the PO format. These initiatives led to TAT being reduced to 3 days, enhancing supplier relations.
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SCM/ Purchase > Strategic Sourcing
Optimizing Strategic Sourcing
A strategic sourcing project was done for a starch manufacturing company. The company had a very large supplier base for corn and it was largely convenience sourcing leading to suboptimal quality of corn resulting in operational issues and lesser yield. The project involved defining key performance indicators such as quality, delivery reliability, cost competitiveness, accessibility and responsiveness. A standardized scorecard template was created, and performance data was collected and evaluated. Suppliers were informed about the new evaluation process and collaborated in setting realistic performance targets. As a result, the company improved the raw material quality, supplier delivery reliability and were able to make more informed strategic sourcing decisions. The project also enhanced risk management by identifying underperforming suppliers early, better controlled process leading to a yield improvement of 6% and strengthened the company’s competitive position through a more efficient and responsive supply chain.
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Operations > Workflow Analysis
Optimizing Water Usage for Sustainability
A sustainability improvement project was done in a beverage plant focused on Water Usage Optimization. The plant faced excessive water consumption and high utility costs, impacting sustainability efforts. To address these issues, project team implemented advanced water recycling systems and installed sensor-based monitoring to track usage in real-time. Additionally, they optimized cleaning-in-place (CIP) processes and upgraded to water-efficient machinery. These solutions enabled the reuse of up to 60% of water, significantly reducing fresh water intake. The project resulted in annual savings of INR 2.5 lacs in water and utility costs. Benefits also included enhanced sustainability through reduced environmental impact, improved compliance with water regulations, and a strengthened corporate reputation for responsible resource management. Furthermore, operational efficiency was boosted, supporting long-term profitability and environmental stewardship.