Physics
Chemical Manufacturer: Formula Optimization ///
Reducing production costs by $1.5M annually through Six Sigma and Design of Experiments without quality loss.
Problem Statement
The manufacturer was facing rising input costs but could not reduce ingredients without risking batch failures and non-compliance with strict quality standards.
Strategic Execution
Our team embedded directly into the production labs. We utilized Design of Experiments (DOE) and Six Sigma methodologies to perform a complete formula optimization, identifying non-critical variables that could be adjusted for cost savings.
$1.5M
Annual Savings
0
Quality Loss
12%
Variance Reduction
6 Sigma
Methodology
Strategic Outcomes
Identified $1.5M in recurring annual savings
Maintained 100% of quality specifications
Upskilled the internal lab team in DOE methodologies
Reduced batch variance by 12%