Reduction of Thickness Variation in XLPE Foam Rolls

The XLPE foam roll production process faces thickness variation, leading to product
inconsistency, customer dissatisfaction, and material wastage. This issue increases
rejection and rework costs, affecting overall efficiency and profitability. The project
aims to identify root causes and reduce variation using Six Sigma tools.
Achieving uniform thickness will improve quality, yield, and customer confidence. It
will also lower scrap rates and enhance process capability. The initiative supports
operational excellence and sustainable cost reduction.

Reduction of Seal Leakage Rate in Sauce Sachet Packaging Process

The current seal leakage rate of 4.94%, sustained over the past nine months, is significantly above acceptable
limits and is leading to substantial operational and business challenges. This high defect rate is driving
increased rejection and rework costs, contributing to wastage of finished goods, and negatively impacting
customer satisfaction and brand reputation due to leakage-related complaints. The organization is currently
incurring an estimated annual loss of ₹18 lakhs due to seal-related defects. By implementing a Lean Six Sigma
improvement project to reduce the leakage rate to 2.0%, the company is expected to achieve annual savings of
approximately ₹10 lakhs while enhancing product quality, customer trust, and overall operational efficiency

Reduction of Scrap percentage in Baking Process

Pizzamania, a rapidly growing pizza chain, invested in modern automated equipment in 2019 to increase production
capacity to 600 pizzas per day. However, the expansion brought several challenges, including process instability and
quality control issues during the transition phase. By early 2021, the internal scrap rate had risen to 17%, and
frequent rework on uncooked pizzas began to reduce the availability of ovens and staff for fresh production

Reduction of Printing scrap rate in Paper Bags

High scrap generation in the printing stage of paper bag manufacturing—currently averaging around 5%—is leading
to significant material wastage, rework, and delivery delays. The primary causes include smudges, print
misalignment, and inconsistent color density, all of which increase the consumption of expensive consumables such
as specialty papers, food-grade inks, and printing plates. These quality issues not only impact production efficiency
but also affect customer satisfaction and brand credibility, especially among key FMCG and retail clients who
demand consistent packaging quality

Reduction of Moisture Content Variation in Fried Instant Noodles

Reduction of Edge Lift / Glass Bending Variation in Solar Panel Tempered Glass

Improvement of First Pass Yield (FPY) in Office Chair Assembly Process