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Lean Six Sigma Project Examples | 17 Full Case Studies

Ready to begin your first Lean Six Sigma project? Looking for examples for inspiration or reference to get you started? Here are some project storyboards from different industries and from home. Remember, Lean Six Sigma can help you with more than just work!

• Reducing Underwriting Resubmits by Over 20%  

Governments

• A Call to Change: Pioneering Lean Six Sigma at Los Angeles County  
• Can Lean Six Sigma Be Applied in County Government?  
• How the City of San Antonio Increased Payments for Street Maintenance Using Lean Six Sigma  
• Reducing Bid Tab Creation Cycle Time by 22%  
• Reducing Cycle Time for Natural Disaster Response by 50%  

Manufacturing

• Increasing First Run Parts From 60% to 90% With Lean Six Sigma  
• Reducing Bent/Scratched/Damaged (BSD) Scrap for Building Envelopes  
• Reducing Lead Time in Customer Replacement Part Orders by 41%  
• Reducing Learning Curve Ramp for Temp Employees by 2 Weeks  
• Reducing Purchase Order Lead Time by 33% Using Lean Six Sigma  
• Herding Cats Using Lean Six Sigma: How to Plan for and Manage the Chaos of Parallel Processes  
• Lean Six Sigma Increases Daily Meat Production by 25%  
• Lean Six Sigma Helps Feed People In Need 45% Faster  
• Accelerating Lean Productivity With Immersive Collaboration  
• Reducing Incorrect Router Installations by 60% for Call One  
• Reducing Software Bug Fix Lead Time From 25 to 15 Days  

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Real-Life Examples of Six Sigma Implementation – Six Sigma Examples/ Use Cases

Six Sigma is a creative and flexible  series of methodologies aimed at improving organizational process quality and effectiveness. This blog on Six Sigma examples will explain a few use cases of Six Sigma methodology. Business today requires companies to be operational at maximum efficiency and effectiveness. The competitive markets mean everyone is looking to distinguish themselves and offer better products and services. A sustainable way to introduce better business practices is by changing your approach fundamentally. 

Companies are built to achieve corporate goals. The methods to achieve them are plenty and streamlined by management for incorporation. The concepts of optimization, minimizing waste, and maximizing productivity are strongly incorporated into the foundation of Lean and Six Sigma principles. 

These business models are conceptual and can be adapted to any industry or business environment. All you need is a guided professional and a willingness to convert your better business practices into the best possible. In this article, let us explore some Six Sigma examples and success stories.

What is Six Sigma?

The definition of Six Sigma has been under much debate. It can be broadly classified into four concepts:

A Philosophy  – Six Sigma is a school of thought that views workflows and activities as processes that can be expounded, quantified, analyzed, bettered, and monitored. It states an input is required to produce an output. Therefore, exercising control over the input gives you a firm hand in managing output. It is sometimes expressed in the equation  y=f(x)  where  x  stands for the input and  y  for the output. 

A Set of Tools –  Six Sigma comprises controls such as qualitative techniques and quantitative tools used to improve business capabilities internally. Six Sigma tools include SPC (statistical process control), FMEA (failure mode and effects analysis), and control charts. Professionals who deal with Six Sigma explain that tools are continually evolving and are not set in stone. 

A Methodology –  Six Sigma is considered to be a derivative of the DMAIC approach . DMAIC is a data-centric improvement method that operates cyclically. It revolves around Defining, Measuring, Analyzing, Improving, and Controlling. This principle drives Six Sigma users to begin by understanding the existing problem and implementing long term solutions. 

A Metric –  When assessing Six Sigma as a metric, it is defined as 3.4 defects per million opportunities.

Six Sigma, in its simplest form, reduces the possibility of variation in production. The objective is to have a firm grasp on the production process. Lean Six Sigma is a term often associated with Six Sigma. Lean methods are used to minimize wastage during production; this includes time and resources spent on processes that do not directly contribute to better output from activities. Lean Six Sigma is a philosophy that brings together waste minimization and production optimization. It improves customer satisfaction by removing unnecessary processes and waste, creating better workflows, faster output, and possibly a competitive advantage. To attest to the importance of Six Sigma, in the next section of this article, let us explore some Six Sigma examples.

Implementing Six Sigma 

Six Sigma can be implemented in a number of strategies, however there are two baseline options provided to all organizations looking to make the transition;

Introducing Six Sigma Training

Organizations can introduce a fundamental revamp across the organization through a Six Sigma program. Expose employees to better practices and conditioning by introducing the fundamentals and allowing a professional to understand what Six Sigma is and what it helps with. It is important to note that it is mostly an information transfer that happens during Six Sigma training . It is up to the business to adopt the methods to the organization and its practices. 

Introducing Six Sigma Infrastructure 

Creating a Six Sigma infrastructure can be quickly moved along by introducing certified professionals into your organization. Often called “Black Belts”, they move into your business for a period of four weeks to four months and begin teaching your business how to adapt the strategies to your activities. Creating the infrastructure creates a firm guideline to make changes to operations and corporate culture. 

Now let us look into some interesting Six Sigma examples and success stories.

Six Sigma Examples

There are several organizations across various industries that have adopted Six Sigma practices to great success . High profile clients include;

General Electric

The American multinational was struggling to improve overall product quality and service even with the best professionals onboarded. After running a six sigma method trial, the company was able to introduce better-streamlining measures into product assurance. As a result, revenue increased. 

This Indian based technology behemoth was the industry frontrunner for consumer goods. However, their customer service was less than satisfactory. Enter Six Sigma. Over time the methods were used to neutralize threats and create a better experience for clients. 

We all know and love the technology giant that gave us Windows and Office. A contributing factor to the success behind their service and products is Six Sigma. The industry leader has made it no secret that Six Sigma methods have enabled better back-end processes and, as a result, better user experience. It acts as a case in point for companies looking to transition into Six Sigma practices. 

The telecommunications company was one of the first to implement six sigma methods. As a trial, the company implemented Six Sigma to assess the impact on improving product quality and streamlining the transition between services to revenue. The positive results created better company-wide performance and permanent incorporation. 

Boeing   Airlines

One of the world’s largest aerospace companies was having issues with air fans within the engines. Unable to pinpoint the exact problem, a group of experts were called in to investigate. They deduced the problem stemmed from FOD (foreign object damage). Upon more in-depth inspection using Six Sigma methods , they could trace the problem to a more fundamental manufacturing issue causing electrical issues along with the FOD. 

Practically, the application for six sigma methods can be seen across any organization attempting to create better output. Introducing better control measures for various parts of the production process helps produce desirable results. 

Final Thoughts

The beauty of Six Sigma methods lies in their ability to adapt to different environments. The increased efficiency and effectiveness are tangible in the success stories of industry giants implementing Six Sigma to success. Add to the real-life Six Sigma examples of by introducing skilled professionals or the Six Sigma infrastructure to your organization. 

The enterprises usually divide their workforce depending on the hierarchy to get their employees trained in different  Lean Six Sigma training programs  in Yellow Belt, Green Belt, Black Belt, Master Black Belt, and Six Sigma Champion. To get a better understanding of which Lean Six Sigma course benefits the most for you or the team, check out some of the popular courses below to get a comprehensive understanding of the same: 

Lean Six Sigma Yellow Belt Certification Training

Lean Six Sigma Green Belt Certification Training

Lean Six Sigma Black Belt Certification Training

Lean Fundamentals Certification Training

Lean IT Certification Training

RCA Through Six Sigma Certification Training

7QC Tools Certification Training

Value Stream Mapping Certification Training

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Top Six Sigma Case Study 2024

Home Blog Quality Top Six Sigma Case Study 2024

Six Sigma is an array of methods and resources for enhancing corporate operations. When Bill Smith was an engineer at Motorola, he introduced it in 1986 to find and eliminate mistakes and defects, reduce variance, and improve quality and efficiency. Six Sigma was first used in manufacturing as a quality control tool. When long-term defect levels are less than 3.4 defects per million opportunities ( DPMO ), Six Sigma quality is reached.

Six Sigma case study   offers a glimpse into how various companies have harnessed the five distinct phases: defining, measuring, analyzing, improving, and controlling, principles of Six Sigma to overcome challenges, streamline processes, and improve across diverse industries.

What Are Six Sigma Case Studies, and Why Are They Important?

Six Sigma case studies examples   show how Six Sigma techniques have been used in businesses to solve issues or enhance operations. For practitioners and companies pondering enforcing Six Sigma concepts, these case studies are an invaluable resource to learn the advantages and efficacy of Six Sigma adoption.

Here are the reasons why six sigma case study is important:

Success Illustration: Case studies demonstrate how Six Sigma projects generate tangible advantages like better productivity, fewer defects, and more customer satisfaction while providing unambiguous evidence of their efficacy.

Learning Opportunities:  They deliver vital insights to use Six Sigma tools and processes realistically and allow others to learn from successful approaches and avoid common errors.

ROI Demonstration:  Case studies provide quantitative data to show the return on investment from Six Sigma projects, which helps justify resources and get support for future initiatives.

Promoting Adoption:  They cultivate a continuous improvement culture and show how Six Sigma concepts can be used in different situations and sectors, which encourages other businesses to embrace the methodology.

Become a Six Sigma Certified Professional and lead process improvement teams to success. Learn how to streamline processes and drive organizational growth in any industry. Join our Lean 6 Sigma training courses and transform your career trajectory with valuable skills and industry recognition.

Six Sigma Case Studies

Let us discuss some real-world case study on six sigma   examples of successful Six Sigma undertakings through case studies:

1. Six Sigma Success: Catalent Pharma Solutions

Do you know how Six Sigma techniques turned things around for Catalent Pharma Solutions?

Six Sigma methodologies, initially presented by Motorola in 1986 and prominently used by General Electric during CEO Jack Welch's leadership, are essential for enhancing customer contentment via defect minimization. Catalent Pharma Solutions, a top pharmaceutical development business, employed Six Sigma to address high mistake rates in its Zydis product line. By applying statistical analysis and automation, training employees to various belt levels, and implementing Six Sigma procedures, Catalent was able to maintain product batches and boost production. This case study illustrates how Six Sigma approaches are beneficial for businesses across all industries as they can improve processes, prevent losses, and aid in cost reduction.

2. TDLR's Record Management: A Six Sigma Success Story

The Texas Department of Licensing and Regulation (TDLR) faced escalating costs due to the storage of records, prompting a Six Sigma initiative led by Alaric Robertson. By implementing Six Sigma methodologies, process mapping, and systematic review, TDLR successfully reduced storage costs and streamlined record management processes. With a team effort and strategic changes, TDLR has achieved significant cost savings and improved efficiency. The project also led to the establishment of a robust records management department within TDLR.

3. Six Sigma Environmental Success: Baxter Manufacturing

Baxter Manufacturing utilized Six Sigma principles to enhance its environmental performance and aim for greater efficiency. Through the implementation of Lean manufacturing and accurate data collection, Baxter reduced waste generation while doubling revenue and maintaining waste levels. With a cross-functional team trained in Six Sigma, the company achieved significant water and cost savings without major investments in technology. It led to promotions for team leaders and showcased the effectiveness of Six Sigma in improving environmental sustainability.

4. Aerospace Manufacturer Boosts Efficiency With Six Sigma

Have you heard about how Six Sigma principles transformed an aerospace parts manufacturer? Here is the 6 Sigma case study   for aerospace parts manufacturer

A small aerospace parts manufacturer used Six Sigma to cut machining cycle time, reducing costs. Key engineers obtained Six Sigma certification and led the project, involving management and operators. Using DMAIC, they analyzed data, identified root causes, and implemented lean solutions. The process yielded a 46% reduction in cycle time and an 80% decrease in variation, enhanced productivity and profitability. The case highlights how Six Sigma principles can benefit businesses of all sizes and emphasizes the importance of training for successful implementation.

Enroll in the  Lean Six Sigma Green Belt certification online training to advance your career! Gain expertise in process improvement and organizational transformation with expert-led training and real-world case studies. Start now to become a certified professional in quality management.

5. Ford Motors: Driving Success

This is a   case study on Six Sigma  i ncorporated by Ford Motors to streamline processes, improve quality, significantly reduce costs, and reduce environmental impact. Initially met with skepticism, Ford's implementation overcame challenges, achieving remarkable results: $2.19 billion in waste reduction, $1 billion in savings, and a five-point increase in customer satisfaction. Ford's Consumer-driven Six Sigma initiative set a benchmark in the automotive industry and proved the efficacy of data-driven problem-solving. Despite obstacles, Ford's Six Sigma exemplifies transformative success in process improvement and customer satisfaction enhancement.

6. 3M's Pollution Prevention Six Sigma Success

Have you checked out how 3M tackled pollution with Six Sigma? It's pretty remarkable. 3M leveraged Six Sigma to pioneer pollution prevention, saving $1 billion and averting 2.6 million pounds of pollutants over 31 years. With 55,000 employees trained and 45,000 Lean Six Sigma projects completed, they focused on waste reduction and energy efficiency. Results included a 61% decrease in volatile air emissions and a 64% reduction in EPA Toxic Release Inventory. Surpassing goals, they doubled Pollution Prevention Pays projects and showcased Six Sigma's prowess in cost-saving measures.

7. Microsoft Sigma Story Lean Six Sigma

By using Lean Six Sigma case studies, Microsoft increased customer interactions and profitability through waste removal and process optimization. They concentrated on improving the quality of the current process and reducing problems by utilizing the DMAIC technique. Eight areas were the focus of waste elimination: motion, inventory, non-value-added procedures, waiting periods, overproduction, defects, and underutilized staff talent. Microsoft streamlined processes and encouraged innovation, which allowed them to maintain productivity and client satisfaction even as technology changed.

8. Xerox's Lean Six Sigma Success Story Six Sigma

It is another important case study of the Six Sigma project. When Xerox implemented Lean Six Sigma in 2003, the organization underwent a significant transformation. They reduced variance and eliminated waste as they painstakingly optimized internal operations. It improved their operational effectiveness and raised the caliber of their goods and services. Through extensive training programs for staff members, Xerox enabled its employees to spearhead projects aimed at improving different departments and functions. The organization saw significant improvements in customer satisfaction and service performance.

9. A Green Belt Project Six Sigma Case Study

It is one of the best examples of a Six Sigma case study. Anne Cesarone's Green Belt project successfully reduced router configuration time by 16 minutes, a remarkable 55% improvement. Anne maintained router inventory, made improvements to documentation and configuration files, and started router requests sooner by resolving last-minute requests and setup mistakes. The initiative resulted in less router programming time from 29 to 13 minutes, an increase in router order lead time of 11 days, and a 60% drop in incorrect configurations. These raised customer happiness and increased operational effectiveness while proving the benefits of process improvement initiatives.

10. Improving Street Maintenance Payments with Lean Six Sigma

Jessica Shirley-Saenz, a Black Belt at the City of San Antonio, used Lean Six Sigma to address delays in street maintenance payments Lean Six Sigma case study examples. Contractors were experiencing extended payment times, risking project delays and city infrastructure integrity. Root causes included payment rejections and delayed invoicing. By implementing quantity tolerance thresholds, centralizing documentation processes, and updating payment workflows, monthly payment requests increased from 97 to 116. Rejected payments decreased from 17 to 12, reducing the rejection percentage from 58% to 42%, saving $6.6 million.

 Six Sigma's effectiveness spans industries, from healthcare to technology. Case studies demonstrate its ability to optimize processes and improve outcomes. From healthcare facilities streamlining patient care to tech companies enhancing software development, Six Sigma offers adaptable solutions for diverse challenges. These real-world examples illustrate how its methodologies drive efficiency, quality, and customer satisfaction. Professionals can learn valuable lessons from using Six Sigma in healthcare studies, identify strategies to overcome obstacles and facilitate continuous improvement. Organizations can emulate best practices and implement similar initiatives to achieve measurable results by studying successful implementations.

Ready to enhance your skills and advance your career with Six Sigma certification? Join our comprehensive KnowledgeHut's best lean Six Sigma courses to master Six Sigma principles and methodologies. Become a sought-after professional in IT, Manufacturing, Healthcare, Finance, and more industries. Enroll now to accelerate your career growth!

Frequently Asked Questions (FAQs)

Six Sigma case studies are available in various formats and places, such as books, academic journals, professional publications, and Internet sites. Many companies that have effectively adopted Six Sigma publish their case studies on their websites or at industry exhibitions and conferences.

Six Sigma case studies provide insightful information on how businesses have addressed certain issues, enhanced procedures, and produced noticeable outcomes. Professionals gain knowledge about best practices, prevalent errors to avoid, and creative problem-solving methods in several industries and circumstances.

Professionals can share their Six Sigma case studies through industry forums, professional networking platforms, blogs, and social media. They can submit their case studies to publications or at conferences and workshops to reach a wider audience within the Six Sigma community.

Shivender Sharma

Shivendra Sharma, an accomplished author of the international bestseller 'Being Yogi,' is a multifaceted professional. With an MBA in HR and a Lean Six Sigma Master Black Belt, he boasts 15 years of experience in business and digital transformation, strategy consulting, and process improvement. As a member of the Technical Committee of the International Association of Six Sigma Certification (IASSC), he has led multi-million dollar savings through organization-wide transformation projects. Shivendra's expertise lies in deploying Lean and Six Sigma tools across global stakeholders in EMEA, North America, and APAC, achieving remarkable business results. 

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Six Sigma in Action: A Case Study at 3M

Introduction to 3m.

3M is the world’s 3 rd most innovative technology company that strives to create groundbreaking products. The goal of 3M is simple – create products that make positive differences in everyone’s lives. Six Sigma specializes management strategy method that has evolved and modernized since its origin in 1986. It focuses on proactively deterring issues that will arise in production and corporate operations. Like many companies have begun to do, 3M acquired the Six Sigma management strategy and has revolutionized its infrastructure. The “World’s Most Ethical Company” is now a leading innovator in technology, energy, and more due to the success of the method. Now, 3M offers an in-depth case study to show exactly how Six Sigma transformed their company.

Implementing Six Sigma

Gaining control of 3M in 2001, James McNerney placed the Six Sigma methodology into the backbone of the company. McNerney’s unique, considerate approach led to a four-year overhaul of the manufacturing and production processes. From eliminating waste to improving productivity, this methodology grew revenue faster than ever and continues to lead innovative technologies.

McNerney grew 3M other enterprises such as Global Souring, 3m Acceleration, eProductivity, and Indirect Cost Control. As a result, 3M began 2005 with over 30,000 employees Six Sigma certified, with a minimum Green Belt training for all technical and sales staff. Combining the Six Sigma methodology with a strong leadership, 3M consistently practices an ever-improving production process with increasing profits to match.

In addition to substantial revenue growth, this methodology continues to bring out massive savings and benefits. The 2003 Annual Report states that operating income was amplified by more than $500,000 in 2002 alone as a result of the Six Sigma initiatives. This figure is substantially larger than earlier predictions, and the forecast continues to remain high for the following year, sitting at $400,000, an estimate which was successfully met as reported by the Prudential Financial Conference in September 2004.

The Results

Alongside considerable financial growth, 3M enjoys significant corporate network growth. 3M’s network continues to expand by collaborating with numerous companies on over 250 projects such as Ford, Estee Lauder, Motorola, Wal-Mart, and Procter & Gamble. Mature, effective Six Sigma programs are easily spotted, sharing their knowledge with customers, suppliers, and other important personnel. Only Six Sigma has the tools necessary to transforming your business, with total process improvements and reducing defects. Six Sigma drives growth, reduces costs, increases revenue, and produces strong business relationships with customers that last a lifetime.

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Category: Case Studies

Case Study: Using Six Sigma in a Non-Six Sigma Culture

Anyone who has worked in manufacturing has probably experienced some level of finger-pointing when shipments fall short of expectations. Though there could be multiple reasons for a missed customer delivery, somehow it is always the other department’s fault. In extreme circumstances, several months of missing targets without effectively defining the root causes and addressing them […]

U.S.A.F. Uses Continuous Process Improvement on the B-2 Bomber: Part 2

In this case study, the 509th Maintenance Group of the U.S. Air Force used an eight-step continuous improvement approach to balance its resources and meet both flying hour program requirements and aircraft availability. Part 1 focused on steps 1 through 4. Part 2 looks at continuing to make improvements with steps 5 through 8. Step […]

U.S.A.F. Uses Continuous Process Improvement on the B-2 Bomber: Part 1

In this case study, the 509th Maintenance Group of the U.S. Air Force used an eight-step continuous process improvement approach to balance its resources and meet both flying hour program requirements and aircraft availability needs. This week looks at steps 1 through 4. Part 2 looks at steps 5 through 8. Introduction The B-2 bomber […]

Project Examples from an LSS Deployment for Cultural Transformation

My company benchmarked against other manufacturing businesses before starting its cultural transformation change. They formed a team and visited companies including Toyota, GM, Milliken, Caterpillar, John Deere, Chrysler, Du Pont and Johnson Controls. After talking to each company about their cultures and continuous improvement processes, my company started to put together a roadmap for transformation. […]

Case Study: Increase Revenue by Decreasing Prices

A division of a diversified organization develops and manufactures samples of new drugs for clinical trials. This work entails different typical manufacturing problems for the following reasons: Quantity requirements can vary from a few grams to several tons from order to order. The effort of research and development (R&D) is central; new processes have to […]

The Cost of Customer Misalignment (& How to Fix It)

This consumer products company has a large portfolio of products. Working with key customers, the company develops and promotes brand marketing programs to help the customer improve their sales which increases the company’s revenue as well. The CEO of the company realized the percentage of successful promotions was less than he expected. At the same […]

Data Transformations Helped One Company Better Analyze Their Process Data

Normality of the data is an underlying assumption for the use of many statistical tools. When normality doesn’t exist, transforming the data may be necessary. Let’s see how one company did that.

How Design of Experiments (DOE) Helped a Pharma Company Extend Product Shelf Life

Through the use of Design of Experiments (DOE), a pharmaceutical company was able to extend the shelf life for one of its life saving liquid oncology medicines. Let’s see how this saved the company money, lowered the price of the drug and helped save lives. 

Chi-Square Analysis Helped This Company Increase Sales by 8.9%

Chi-square analysis is a powerful tool for examining the relationship between variables formatted in a table. One consumer products company used it to look at its consumers in a different way, resulting in a significant increase in sales and profitability of its product portfolio.  Traditionally, an organization’s sales and marketing department makes advertising decisions based […]

Using Failure Modes and Effects Analysis (FMEA) Reduced Adverse Medical Events at This Hospital

After experiencing multiple adverse medical events, one large hospital system moved from the sole use of a reactive root cause analysis approach to include a proactive Failure Modes and Effects Analysis strategy, which significantly reduced adverse medical events.  As was the strategy at the time, a large tax supported public health system relied on root […]

Conjoint Analysis Helped This Company Develop a Blockbuster New Packaging Design and Sell More Product

Stop guessing what your customers value in your product or service. Use conjoint analysis to determine what features are most important to them and have the data to support your decisions. Conjoint analysis is often described as a design of experiments (DOE) for marketing. It is a structured way to help you identify and evaluate […]

Basic Six Sigma Tools Helped This Company Reduce Waste and Product Rejections

How hard can it be to make orange juice? As one large global company found out, no single Six Sigma tool will solve all the problems in an organization. However, the integration of a number of tools such as correlation, Measurement System Analysis (MSA), control charts, and process capability will help solve many of them.  […]

Using Binary Logistic Regression Helped a Global Financial Company Win More Business 

Let’s look at the financial division of a global conglomerate. One of its businesses was providing loans to corporate clients. Although a dominant player in the market, the company still had to compete with other organizations to provide financing and lending to myriad businesses. By using binary logistic regression to help refine its lending offers, […]

Control Charts and Employee Engagement Helped This Company Save Over $150,000 in One Year 

Providing the proper organizational environment for engaging people in your continuous improvement effort will provide large benefits for your organization. In this study, we look at how the combination of using control charts and providing an environment for people engagement helped one company achieve significant financial benefits. Control charts are a powerful tool for understanding […]

Verifying Their Data With Measurement System Analysis (MSA) Saved This Company $1M

Most businesses today brag about how they make data driven decisions on important company issues. But, what if the data is not accurate or reflective of what is really going on in the company? You might be making the wrong business decisions and inadvertently costing your company lots of money. Let’s see how one company […]

How Root Cause Analysis (and Employee Engagement) Can Save Lives and Prevent Injuries

A company producing commercial ink products noticed that injury rates during one step in their manufacturing process were rising after the introduction of a new product. A Lean Six Sigma Master Black Belt (MBB) consultant was hired to help the company try to resolve this serious problem. Was there a simple solution, or would it […]

Using SIPOC-(R) to Assess Team Culture Leads to Meaningful Dialogue About Communication

Culture is the “white whale” of leadership: in Moby Dick, Captain Ahab was obsessed with capturing the white whale, and modern leaders have a similar obsession with developing organizational culture.  Lean Six Sigma organizations task themselves with fostering a culture of continuous improvement (or kaizen) that draws from customer requirements, objective data and metrics, and […]

Case Study: Using RACI and Swimlane in the Pandemic

The problem: Healthcare providers needed to safely care for patients over the course of the pandemic. But how could they keep everyone safe without adequate supply of N95 masks?

Improved Rescue Time from a Bolling Mill Machine

While a Bolling mill machine creates uniform sheets of rubber with ease, it also poses a danger to an operator’s hands. Reducing rescue time and improving safety measures made for a successful Yellow Belt project in one lab.

Quick Wins Can Successfully Launch Operational Excellence in Healthcare

If the Mayo Clinic can do it, so can you! Let this case study at the medical organization’s Phoenix Transplant Center be your guide to operational excellence in healthcare settings.

Case Study: Streamlining a Hiring Process

How do you elevate a recruiting free-for-all into a standardized, efficient and well-respected process that gets new hires in the door faster? Hello, Lean Six Sigma!

Case Study: Edward Jones Adds Robotic Process Automation with Lean Six Sigma

In only three years, Edward Jones has realized more than a million dollars in cost avoidance through the use of bots combined with LSS.

Case Study: DMAIC Project Improves Hospital’s On-time Completion of Administrative Tasks

Healthcare is a heavily regulated industry and requires substantial amounts of paperwork. Paperwork may not be as pressing as patient care, but it must be done in a timely fashion. A Lean Six Sigma project reduced the task delinquency rate in its residency program.

Case Study: Reducing Purchase Order Cycle Time, Part 2

A Green Belt project aimed at reducing the cycle time for purchase orders finds the bottleneck and dramatically improves the process, exceeding the project’s original goals, and even realizes bonus benefits.

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Lean Six Sigma Case Studies

Welcome to the Lean Six Sigma Academy’s Case Studies section! Here, you will find a collection of real-world examples of how companies have successfully implemented the Lean Six Sigma methodology to improve their business operations. Each case study includes an overview of the business challenge that was faced, the approach that was taken, the results that were achieved and feedback from the client on their experience. These case studies showcase the wide range of industries and organizations that have benefited from Lean Six Sigma, and serve as inspiration and guidance for those looking to implement the methodology in their own business. 

OE Partners

Orrcon Steel

The toyota production system.