A three-year Lean Six Sigma transformation partnership with a leading pharmaceutical manufacturer — from belt-level capability building to on-site changeover excellence.
The client operates two manufacturing sites in India, producing a diverse portfolio of dosage forms across solid and semi-solid manufacturing. With a strong commitment to quality, compliance, and operational efficiency, the organisation sought a structured, data-driven improvement programme to eliminate chronic losses, reduce variability, and build sustained internal capability in Lean Six Sigma.
Stat Modeller was engaged as a long-term improvement partner to build lasting Lean Six Sigma capability while directly tackling the plant's biggest source of downtime — changeover time — through dedicated on-site consulting.
Structured Yellow Belt and Green Belt training delivered across both sites, equipping shop-floor teams and engineers with a common language for problem-solving and process improvement.
End-to-end DMAIC project coaching for 22 belt-level projects, ensuring rigorous application of statistical tools, root cause analysis, and tollgate-based progression from Define through to Control.
On-site application of SMED methodology across Granulation and Compression units in 3 operational areas, driving structured changeover reduction through waste elimination and standardisation.
Total validated financial savings of more than ₹120 Lakhs delivered across both sites — combining hard savings (cost reduction, waste elimination) with soft savings (productivity and throughput improvements). Return on investment significantly exceeded programme costs.
A self-sustaining cadre of certified Green Belt and Yellow Belt practitioners now leads improvement work independently at both sites, backed by a structured governance model — tollgate reviews, savings validation, and control plan documentation — embedded as standard practice.
“The engagement with Stat Modeller has been transformational — not just in terms of financial savings, but in building a mindset of continuous improvement across our teams. The rigour of DMAIC, combined with hands-on SMED implementation, has equipped our people with skills they continue to apply every day.”— Pharmaceutical Manufacturing Client
Deep domain knowledge in pharmaceutical and manufacturing sectors, enabling contextually relevant training, tooling, and project selection.
From training design through project closure, savings validation, and control plan handover — a single accountable partner across the entire improvement lifecycle.
A long-term partnership approach that builds lasting internal capability rather than a one-time intervention — ensuring improvement gains are sustained and scaled.
Let's talk about what a structured Lean Six Sigma and SMED programme could look like for your organisation.
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