Indian businesses today face rising input costs, global competition, quality pressure, and shrinking margins. Whether you are in manufacturing, logistics, FMCG, or infrastructure, improving efficiency is no longer optional — it’s survival.

This is where lean six sigma consulting services India companies rely on play a transformative role.

At Faber Infinite Consulting, we have worked across multiple industries in India and Africa, helping organizations reduce waste, improve productivity, and drive measurable financial impact through structured Lean Six Sigma implementation.

This blog explains:

• What lean six sigma consulting really includes
• Benefits of lean six sigma India businesses achieve
• Cost expectations
• How to choose the right consultant
• Real-life implementation insights
• FAQs decision-makers often ask

What Is Lean Six Sigma Consulting?

Lean Six Sigma combines:

• Lean Manufacturing – Eliminating waste
• Six Sigma – Reducing process variation

The methodology originated from systems developed by Toyota Motor Corporation (Lean Production System) and statistical quality systems formalized at Motorola in the 1980s.

Today, Lean Six Sigma is a globally recognized standard supported by bodies like American Society for Quality.

In India, it is widely used across:

Industry	Common Use Case
Manufacturing	OEE improvement, rejection reduction
FMCG	Line balancing, manpower optimization
Logistics	TAT reduction, route optimization
Infrastructure	Project cycle time reduction
SMEs	Cost control & process stabilization

Why Indian Businesses Need Lean Six Sigma Now

India’s manufacturing sector is expected to reach $1 trillion by 2025 (as per Government of India targets). However, many companies struggle with:

• High rework & scrap
• Low manpower productivity
• Equipment breakdowns
• Process variability
• Inventory pile-up

Benefits of Lean Six Sigma India Companies Experience

Benefit	Business Impact
Waste Reduction	10–30% cost savings
OEE Improvement	15–25% output increase
Defect Reduction	30–70% quality improvement
Inventory Optimization	Improved cash flow
Standardization	Reduced dependency on individuals

At Faber Infinite, we’ve seen mid-sized plants improve EBITDA margins by 2–5% within 6–9 months of structured lean six sigma implementation India programs.

Top Lean Six Sigma Consulting Services in India

Here is what expert lean six sigma consulting typically includes:

1. Diagnostic & Value Stream Mapping

Activity	Outcome
Current state assessment	Baseline performance data
Process mapping	Identify bottlenecks
Waste identification	Immediate quick wins

We conduct plant diagnostics covering productivity, layout, manpower efficiency, and decision bottlenecks.

2. DMAIC Project Execution

DMAIC stands for:

• Define
• Measure
• Analyze
• Improve
• Control

Phase	Focus
Define	Business problem clarity
Measure	Data collection & validation
Analyze	Root cause identification
Improve	Pilot solutions
Control	Sustain results

Our lean six sigma project mentoring ensures internal teams own the improvement, not just consultants.

3. Cost Reduction & Process Excellence Consulting India

Area	Approach
Manpower Productivity	Time & Motion Study
Machine Downtime	TPM integration
Layout Optimization	Lean flow design
Inventory	Pull system design

We integrate Lean Six Sigma with operational excellence services, not as isolated projects.

4. Lean Six Sigma for SMEs in India

SMEs often assume Lean Six Sigma is expensive.

Reality:

SME Myth	Reality
Only for large corporates	Highly effective for SMEs
Requires big data systems	Can start with basic Excel
Long duration projects	Quick wins possible in 60 days

Our affordable lean six sigma services model allows SMEs to implement modular improvement programs without disrupting operations.

Real Experience: Case Snapshot

FMCG Manufacturing Unit – Western India

Problem:

High manpower cost and inconsistent output.

Intervention:

• Line balancing study
• Waste identification
• Standard operating procedures
• Performance dashboard implementation

Results in 5 Months:

Metric	Before	After
Output	100% baseline	+18% increase
Manpower cost	100% baseline	-12%
Rejection rate	6%	3.2%

This is the power of structured lean six sigma implementation India programs when combined with management alignment.

How Much Do Lean Six Sigma Consulting Services Cost?

(One of the most searched long-tail queries)

Company Size	Typical Investment Range
SME	₹3–8 Lakhs
Mid-size manufacturing	₹8–25 Lakhs
Large enterprise	Custom structured engagement

Cost depends on:

• Scope of intervention
• Number of processes covered
• Duration (3–12 months)
• On-site vs hybrid consulting

ROI is typically 3x–8x within the first year if implemented correctly.

How to Hire a Professional Lean Six Sigma Consultant Online?

Here’s a practical checklist:

Criteria	What to Check
Experience	Industry-specific case studies
Approach	Structured DMAIC framework
ROI clarity	Defined financial targets
Team capability	Certified Black Belts
Sustainability plan	Control mechanisms post-exit

Ask for:

• Measurable past results
• Project governance structure
• Clear scope definition

Why Choose a Lean Six Sigma Consultant for Process Efficiency?

Internal teams often struggle because:

• They are busy with daily firefighting
• Lack statistical expertise
• Face resistance to change

External consultants bring:

Advantage	Impact
Neutral perspective	Faster decision making
Data-driven tools	Reduced subjectivity
Cross-industry exposure	Faster benchmarking
Structured governance	Sustained improvements

At Faber Infinite Consulting, we focus not just on tools but on building an internal continuous improvement culture.

Lean Six Sigma & Industry Standards

Lean Six Sigma aligns with:

• ISO 9001 quality standards
• TPM frameworks
• Kaizen principles
• Industry 4.0 integration

Many Indian exporters adopting global standards use Lean Six Sigma as a foundation for compliance and competitiveness.