Your cart is currently empty!
Consulting
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
-
Business Analytics > BI Dashboard
SCM/ Purchase > Supplier QA
Quality Control/ Quality Assurance > Supplier Quality ManagementSupplier Quality Dashboard Integration
A dashboard creation project was implemented for real time monitoring of supplier QA for an FMCG company working with a large number of suppliers. The issue identified were lack of well defined KPIs for suppliers, multiple sources for data for supplier quality, no real time numbers for quick decision making. The project addressed these concerns by defining KPIs for each supplier, consolidating data from multiple sources and creating real time dashboards using Microsoft Power BI. Extensive trainings were conducted in-house and suppliers were sensitized about the new QA monitoring mechanism. This resulted in centralized tracking of supplier quality thereby releasing bandwidth of 4 resources.
-
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.
-
Risk Management > Fraud
Quality Control/ Quality Assurance > Lean Six Sigma
Lean Six Sigma > LSSBB
Quality Control/ Quality AssuranceRefining Credit Fraud Detection
A Lean Six Sigma Black Belt project was carried out at a leading bank which aimed to reduce the false negative rate in credit card fraud detection by 30% within six months. The project involved analyzing the root causes of missed fraudulent transactions, refining detection algorithms, incorporating additional data points, and using advanced simulation techniques. The outcome was a significant annual reduction of approx. 3.65 lacs INR in financial losses due to fraud, with enhanced accuracy and confidence in the fraud detection system leading to greater customer confidence.
-
Quality Control/ Quality Assurance > Process Capability
Building Vendor Capability Metrics
A process capability model was developed for the vendor management department of an organization. The key issue identified was having no visibility on vendor performances and no way to compare their performances (as all vendors used their own capability metrics). The team used to do a monthly and quarterly review but it was more with a lag of at least a month. The vendor management team wanted a more real time monitoring of the vendor performance and also be able to compare them. A comprehensive study was conducted on all vendor processes and a robust model was built where Sigma Levels were calculated for all vendors on a weekly basis. This ensured quicker monitoring and a suitable method to compare their performance. This project was able to streamline the vendor management department and resulted in savings of INR 23 lacs by removing the low performing vendors.
-
Quality Control/ Quality Assurance > FMEA
Comprehensive Risk Assessment Implementation
A risk assessment project was done for a IT services provider. The company wanted to understand the risks involved in all their processes and also wanted to have a mitigation plan for them. Project involved creating detailed process maps followed by FMEA for all the processes. Basis the RPN calculated a comprehensive list of solutions were devised to systematically reduce the risks in the processes. The project resulted in a potential saving of INR 50 lacs in terms of penalties and fines.
-
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.
-
Quality Control/ Quality Assurance > RCA
Redefining Root Cause Analysis
A Root Cause Analysis training project was conducted for a banking back office where the approach was redefined to draw the current state diagrams identifying the current issues and their actionable causes, draw the conflict resolution diagrams to identify the conflicts in resolving these actionable causes, draw the future state diagram to depict how the issues are getting resolved by implementing the injections. This design thinking approach revolutionized the RCA process in the bank. It was easier to work with cross functional teams and the bank was able to save a lot of time that it used to spend doing RCA in silos and then getting into conflict resolutions.
-
Quality Control/ Quality Assurance > Sampling, Inspection and Testing
Improving Sampling Techniques for Quality
An automotive OEM was facing the problem of frequent customer complaints and rejections even when the batches were internally inspected. The issue identified was the use of convenience sampling technique leading to a biased and very small sample size. A project was undertaken to statistically determine the correct sample size and identify the best sampling technique based on the nature of the processes. SOPs were updated and staff was trained to ensure sustenance of the project. The project resulted in 70% less customer complaints and 65% less customer rejections.