When internal initiatives failed to curb rising scrap costs, one of our key clients turned to KCG to lead a structured, results-driven transformation using the DMAIC Six Sigma methodology.
The Challenge
- Internal scrap costs significantly exceeded targets
- Previous improvement programs showed limited impact
- A decision was made to adopt a Lean Six Sigma approach to drive real, measurable change
The Objective
- Launch and execute 6 focused projects led by 5 trained project leaders
- Deliver a cost saving of €600,000 in just 9 months
- Build internal capability while achieving immediate operational impact
The Approach
- Applied full DMAIC roadmap: Define, Measure, Analyze, Improve, Control
- Combined Lean tools (e.g., VSM, problem solving) with Six Sigma tools (SIPOC, C&E Matrix, MSA, DoE, FMEA)
- Project leaders selected and assessed using the Structogram method
- Delivered workshops, 1:1 coaching, and transparent performance reviews
- Embedded best practices, templates, and benchmarks across all projects
The Results
- 5 projects completed and handed over to operations
- €585,000 savings confirmed (Jan–Sept 2020, validated by Controlling)
- 33 One-Point Lessons (OPLs) created and partially reused in new launches (30–40%)
- 95% positive feedback via Net Promoter Score
- Client approved a 3-year Lean Six Sigma roadmap including Green & Black Belt development, aiming for €1M annual savings
This success demonstrates the power of structured execution, hands-on coaching, and data-driven decision-making.
At KCG, we don’t just implement tools—we build capability and deliver sustainable results.
