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Success Stories

saves $10 million through lean six sigma initiative

The Economic Times article about
MGBS Success in Vestas


Vestas Wind Systems A/S is a Danish manufacturer, seller, installer, and servicer of wind turbines. It is the largest in the world, but due to very rapid growth of its competitors, its market share decreased from 28% in 2007 to 12.5% in 2009. The company operates manufacturing plants in Denmark, Germany, India, Italy, Romania, Britain, Spain, Sweden, Norway, Australia, China, and the United States, and employs more than 20,000 people globally.

Revenue                     €6.920 billion (2010)

Operating income      €310 million (2010)

Profit                           €156 million (2010)

Total assets                €7.066 billion (end 2010)

Total equity                €2.754 billion (end 2010)

Employees                 20,400 (January 2012)


 Unplanned Downtime at Wind Turbine UnitWe have:

  • Improved Turbine Monitoring and Surveillance

  • Increased availability of technical staff on 24-7 basis to address breakdown

  • Increased spare parts availability to address emergency      part replacement

  • Created easier access to tools needed during breakdowns

This improvement plan has helped customer reduce unplanned downtime from 60 to 10 Hours/Month yielding a direct annual cost avoidance of US
$ 1.0 Million in the form of liquidated damages.

 Wind Turbine Casting HUB Hole Drilling QualityWe have:


  • Reduced variation among the operator skills;

  • Held operational manpower accountable;

  • Trained operating team members use efficient tools to improve quality;

  • Taken steps to use a lower hardness for casting material of construction

  • Provided process information to help improve the drilling parameters

The improvement action plan has resulted in reducing defect rates from 12 % to 0.7 %, yielding a direct annualized benefit of about US $ 1.1 Million.


RevenueUS                         $ 82.55 billion (2011)

Operating incomeUS          $ 15.81 billion (2011)

Net income                         US$ 11.79 billion (2011)

Total assets                        US$ 138.35 billion (2011)

Total equity                        US$ 68.00 billion (2011)

Employees                         129,000 (2011)

Gillette is a brand of Procter & Gamble currently used for safety razors, among other personal care products. Based in Boston, Massachusetts, United States, it was one of
several brands originally owned by The Gillette Company, a leading global supplier of products under various brands, which was merged into P&G in 2005. The original Gillette Company was founded by King Camp Gillette in 1901 as a safety razor manufacturer.

Gillette razor Cartridge Injection
Molding Performance

The Gillette Mach 3, the first triple-blade razor has become the world’s leading razor. Three specially positioned suspended blades shave you closer in a single stroke. And each Gillette Mach 3 blade comes equipped with DLC™ comfort edges allowing Mach 3 to glide effortlessly across your face for a close, comfortable shave.
Gillette MACH 3 fundamentally reengineered the blades – the first major blade innovation since the 1960′s. The edges are thinner than any other Gillette blade. With MACH 3 you experience less drag and pull and an extraordinarily comfortable shave. The aligned MACH 3 blades combine to
deliver the closest shave in fewer strokes with less irritation.


 Improvement Action Plan was:


  • Run to production plan consistently

  • Develop color of polymer pellet to meet customer needs

  • Standardize SOP – 5 S across manufacturing floor

  • Match measurement systems between customer and vendor

  • Eliminate regrind in product processing mix

  • Justify new specifications based on new test method

  • Monitor test instrument performance for consistency

  • Ensure gauge accuracy and stability for qualifying product

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