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Case Study · Lean Six Sigma Capability Building

Driving ₹48 Crore in Savings at a Leading Cable Manufacturer

A long-term Lean Six Sigma partnership across two manufacturing sites — from shop-floor capability building to validated financial impact.

IndustryCable Manufacturing
Engagement4+ Years · Ongoing
Sites2 Manufacturing Sites
Talk to Us About Your Improvement Goals
Cable and conductor reels on the manufacturing floor
149
Total Participants Trained
70
GB + BB Combined Certified
₹35 Cr
Cost Savings Realised
₹40 Cr
Savings in Pipeline
Client Snapshot

A leading name in Indian cable and conductor manufacturing

The client operates two large-scale manufacturing facilities producing power cables, speciality cables, and conductors, serving critical sectors including energy, infrastructure, and telecommunications. With thousands of employees across both sites, the organisation recognised the need for a structured, data-driven improvement culture to sustain its competitive position amid escalating operational complexity.

The Challenge

Five hurdles standing between the business and sustainable improvement

01No structured problem-solving methodology across production functions
02No qualified internal improvement pipeline at Green Belt or Black Belt level
03Significant cost leakage with no systematic measurement or root-cause framework
04Siloed operations across two sites with inconsistent practices
05Limited shop-floor buy-in for data-driven decision making
Our Approach

A phased, DMAIC-led capability build

Stat Modeller was engaged as a long-term improvement partner to design and embed a scalable Lean Six Sigma capability framework — combining structured classroom learning, live project coaching, and cross-site knowledge integration.

01

Assess & Design

Custom curriculum designed and mapped to the client's cable manufacturing processes.

02

Train & Coach

Green Belt and Black Belt cohorts trained alongside live, real-plant project execution.

03

Embed & Sustain

Certification, governance, and pipeline expansion embedded as standard practice.

Each cohort followed the rigorous DMAIC (Define–Measure–Analyse–Improve–Control) framework, with participants solving actual plant problems under Stat Modeller's expert guidance. Projects were selected for strategic alignment, measurability, and cross-functional impact.
Key Outcomes at a Glance

Belt-level performance across both sites

KPIGreen Belt (GB)Black Belt (BB)
Participants Trained12623
Participants Certified691
Cost Savings Realised₹26 Crore₹9 Crore
Cost Savings in Pipeline₹22 Crore₹18 Crore

Combined Savings (Realised + Pipeline): ₹75 Crore across 2 Manufacturing Sites

Areas of Impact

Impact spanning operations, people, financials, and governance

Operational Excellence

  • Significant reduction in process waste and rework rates
  • Improved OEE (Overall Equipment Effectiveness) in cable extrusion lines
  • Standardised SOPs adopted across both manufacturing sites
  • Reduced defect rates in conductor drawing and insulation processes

People & Culture

  • Built an internal belt community of 70 certified improvement practitioners
  • Structured mentoring model — BB candidates coached by Stat Modeller's Master Black Belts
  • Improved cross-functional collaboration between quality, production, and engineering teams

Financial Performance

  • ₹35 Crore in validated cost savings realised through certified projects
  • ₹40 Crore in savings actively progressing through the improvement pipeline
  • Projects spanning raw material yield, energy optimisation, and scrap reduction

Programme Governance

  • 4+ year continuous partnership demonstrating deep organisational trust
  • Structured tollgate reviews ensuring project rigour and financial validation
  • Executive steering committee aligned to improvement goals at both sites
“The Lean Six Sigma journey with Stat Modeller has fundamentally transformed how our teams approach problems. The financial impact has been significant, but the cultural shift — building a pipeline of certified improvement leaders within our own workforce — is what makes this engagement truly strategic.”
— Senior Leadership, Cable Manufacturing Client
Why Stat Modeller

What made this partnership work

Industry-Aligned Curriculum

Training content built around cable and conductor manufacturing realities, not generic templates.

Project-Led Certification

Every belt earned through real projects with measurable, validated financial impact — not classroom tests alone.

Long-Term Partnership

4+ year continuous engagement with ongoing coaching, pipeline expansion, and governance support.

Ready to build your Lean Six Sigma capability?

Let's talk about what a structured, data-driven improvement programme could look like for your organisation.

Talk to Us
+91 73839 60590 contact@statmodeller.com Vadodara, Gujarat, India

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