Integrated Steel Manufacturer
Inefficiencies and high rejection rates were holding back growth. Through a Lean Six Sigma roadmap, structured quality systems, and customer feedback loops, the manufacturer reduced waste, improved throughput, and secured stronger market positioning in a competitive industry.
1
The Challenge
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Bottlenecks and inefficiencies reduced throughput
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High rejection rates raised costs and hurt customer trust
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Weak customer feedback limited improvements
2
Our Approach
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Roadmap: Phased Lean Six Sigma plan (short-, mid-, long-term)
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Process Mapping: Baselines via value stream mapping, OEE benchmarking, defect classification
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Quality Tools: SPC, FMEA, CAPA, audits across production lines
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Customer Voice: Structured complaint management and delivery tracking
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Workforce: Skill-gap analysis, training, Kaizen boards, problem-solving teams
3
The Results
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Waste and defect reduction across production lines
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Improved throughput with less downtime
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Stronger customer retention via quality and reliability
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Differentiated market positioning, enabling pricing premium
4
Strategic Value
Delivered a blueprint for sustainable competitiveness, balancing operational excellence with strong customer trust.
Get in Touch
Hema Vetekar +91 99309 99203