Case Studies

Methodology	Industry Project Area	Focus	Key Tools	Results
Six Sigma Lean Click to view case study	Large Equipment Manufacturer Invoice & Collection Process	Reduce Days sales outstanding by 4 days, minimum, in order to increase cash flow	Process Map, Cause and Effect, FMEA, Multivariable Analysis, Control Plan	With in 5 months, reduced days sales outstanding across 52 sales offices from 52.2 days to 48 days, > $9.5 million in increased cash flow
Six Sigma Lean Click to view case study	Pharmaceutical Chemical formulation process	Reduce amount of key expensive chemical in reaction without increasing amount of un-reacted agent, in order to reduce cost	Design of Experiments, Multiple Response Optimization	Reduced amount of chemical required:  > £100,000 / year savings
Six Sigma Lean Click to view case study	Automotive Supplier Multi-cavity Mold	Reduce variation in key dimension on part in order to maintain (not lose) business	Process Mapping, Prioritization matrix, FMEA, Measurement Systems Analysis, Design of Experiments	Reduced variation of key dimension 70%: Selected as key supplier
Six Sigma Lean Click to view case study	High Volume Equipment Manufacturer Manufacturing Extrusion and Forming  Process	Reduce variation in key dimension in order to response to  customer rejection  of 700,000 units	Process Map, Cause and Effect, FMEA, Multivariable Analysis, Control Plan	Reduced variation of key dimension by 75% Maintained key customer contract, doubled sales
Methodology	Industry Project Area	Focus	Key Tools	Results
Business Process Management Systems Click to view case study	Electronic defense Human Resources		Customer and needs identification, Value Chain Mapping, Prioritization Matrix,  Value Profile Survey, Process Mapping, Gap Analysis	Identified cost gap of > $1.2 million/ year Prioritized projects to address and close gap
Design Six Sigma: Technical Product and Process Click to view case study	Electronics Design, Test and assembly	Decrease reject rate of component by a factor of 10 in order to reduce rework, scrap, inventory	Measurement Systems Analysis,  Statistical Graphical Analysis, Statistical Tolerancing	Sourced new supplier >$700,000Savings/ year
Design Six Sigma: Service and Process Click to view case study	Insurance Administrative Process	Increase set up accuracy from 83% to 99%, in order to reduce rework	Customer interviews, KJ, QFD, Process Mapping, FMEA, Statistical Graphical Analysis	Decreased rework and non value add: >$150,00 savings Increased customer satisfaction >$400,000increased revenue
Innovation Six Sigma Click to view case study	Medical Nutritional Products Health Care Market	Identify key opportunities in the growing health care market	Opportunity ID,  Outcome analysis, Customer Value Chain, Perceived  Quality Survey	Identified an untapped opportunity, created new market Business sold to major pharmaceutical firm