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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.
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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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Implementing Sustainable Power Solutions
A project was done for a telecom infrastructure company. The company faced high operating costs due to excessive diesel consumption and frequent theft of diesel fuel at tower sites reliant on generators amid unreliable grid power. To tackle these issues, the team integrated solar panels and advanced battery storage with existing generators and installed remote monitoring systems to deter theft. This hybrid solution reduced diesel usage by 40%, from 1,000 to 600 liters per tower per month, and decreased theft incidents by 85%. As a result, the company saved approximately INR 90 lacs annually in operating costs across all towers in one circle. The project not only cut expenses and minimized environmental impact but also enhanced security at tower sites.
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Automating Back-Office Operations
A project was done to remove the bottlenecks in the back office processes at a shipping company. The company faced delays and errors due to manual back-office processes such as invoicing, scheduling, and compliance reporting. These inefficiencies led to extended turnaround times, increased operational costs and dissatisfied customers. To resolve this issue, the project team implemented RPA to streamline the tasks. As a result, invoicing processing time decreased by 50%, from 48 hours to 24 hours. The company reduced back-office headcount by 15 employees, saving approximately INR 10 lacs annually. Overall, the automation led to quicker turnaround times, reduced headcount, improved accuracy, and significant cost savings.