How to Improve Process Productivity for MSMEs: Lean Six Sigma Approach
A Practical, Execution-Focused Approach for Indian Manufacturing Businesses

Improving Productivity in Manufacturing: Beyond Machines & Manpower

Lean Six Sigma is a proven methodology that enables MSMEs to significantly improve process productivity by systematically eliminating waste, reducing defects, and stabilizing core operations—without the need for heavy capital investment. By focusing on process efficiency, flow improvement, and variation reduction, MSMEs can achieve faster cycle times, improved throughput, and better utilization of existing resources.

At D&V Business Consulting, we apply a structured and practical Lean Six Sigma approach tailored specifically for Indian manufacturing environments. Our engagement focuses on hands-on shop-floor execution, line balancing, standard work implementation, and data-driven decision-making to improve cycle time, turnaround time, inventory control, and overall productivity. With a strong execution focus, MSMEs typically achieve 10–30% productivity improvement within 6–10 months. Headquartered in Ahmedabad with a pan-India presence, D&V Business Consulting partners with manufacturing businesses to unlock hidden capacity and build sustainable, scalable operations.

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    High Process Variability and Inconsistency
    Why Process Productivity Is a Challenge for MSME Manufacturing Units

    If you are running a manufacturing unit there are chances you are busy- but profitability is not increasing as expected.

    • Production targets are met, but cost keeps on increasing

    • Teams are working hard but then also the orders are delayed

    • Efforts are just for week and then everything fades and come to how it was

    • Defect and rework rate is high which somehow is decreasing productivity

    That doesn’t mean there is problem with the team. The problem is process.

    At D&V Business Consulting, we have seen this pattern repeatedly across manufacturing units and company. The businesses don’t lack effort, but structured process improvement.

    This is where our Lean Six Management consulting becomes a game-changer.

    What Is Process Productivity in Manufacturing?

    Process productivity means how effectively the inputs-man, machine, method and money are converted into desired outputs consistently and with minimum waste.

    It answers the questions like:

    • How much output do we get per employee per shift?
    • How much Is the production time vs waiting, reworking and correcting the mistakes?
    • Is quality, delivery and process consistent?

    High productivity doesn’t mean working fast but means working in smarter manner that you can increase your productivity through stable and repeatable process.

    Why Process Productivity Directly Impacts MSME Profitability

    We have seen that in many MSMEs and mid- sized manufacturing organizations, there is growth. Increased number of orders, good team and new machines.

    This typically happens when: 

    • Processes are manual, not system driven
    • Supervisors work on intuitions not on data.
    • Management in engaged in daily operations instead of working on planning and strategy making
    • Quality issues even after corrective measures

    At this stage, increasing revenues are no longer metric that turn into higher profits

    In today’s fast moving world businesses can’t afford to waste time on things that don’t work well. This is D&V Business Consulting steps in with their structured process productivity improvement program using Lean Six Sigma.

    Why Traditional Productivity Improvement Methods Fail in MSMEs

    Many businesses try improving productivity through:

    • Cost- cutting
    • Hiring more supervisors and people.
    • Buying new machines
    • Pushing team to achieve targets

    These actions would treat the symptoms but not root causes.

    Without data, Standard of processes and accountability improvement can’t sustain for longer.

    Lean Six Sigma: The Practical Framework for MSMEs

    Lean Six Sigma is not a tool or certificate that an industry need. It is a management philosophy which is supported by data, discipline and execution rigor.

    At D&V Business Consulting, Lean Six Sigma is used as a business transformation framework, not just a theory. It helps the manufacturing businesses with operational excellence.

    Lean focuses on identifying and eliminating activities that do not add value to process

    Common wastes observed in MSMEs include:

    • Excess movement due to poor factory layout
    • Underutilization of skilled manpower
    • Operators waiting for approvals and materials
    • Overproduction causing inventory pile-ups

    Eliminating these wastes can result in immediate productivity gains. Process Excellence Program of D&V Business Consulting helps you identify the root cause and the activities that are not adding value but only wasting the time and resources of the business.

    Lean Six Sigma The Practical Framework for MSMEs

    Lean Manufacturing: Eliminating Waste on the Shop Floor

    Six Sigma focuses on reducing process variation and establishing the productive work environment by D&V Business Consulting

    As variation leads to:

    • Inconsistency
    • Unplanned downtime
    • Late delivery
    • High inception and rework cost

    By stabilizing processes, Six Sigma ensures that productivity is maintained and increased.

    The DMAIC Execution Approach Used by D&V Business Consulting 

    1. Define Phase in Lean Six Sigma

    We begin with aligning improvement goals with the expected outcomes.

    Typical focus areas:

    • Low OEE
    • High rejection rates
    • Inconsistent quality
    • Poor utilization of resources
    • Delay in delivery
    1. Measure: Data Before Decisions

    Businesses work on intuitions and perspectives, consultants at D&V Business Consulting rely on data:

    We build foundation through:

    • Process mapping
    • Time studies
    • Manpower productivity metrics
    • Rejection and downtime data

    Like Cycle time, Error percentage, value -added time, non- value-added time, etc.

    1. Analyze: Identifying the Root Cause

    As an experienced consulting in India, D&V Business Consulting identify the causes for inefficiency by using tools like:

    • Fishbone Analysis
    • Pareto analysis
    • 5 Whys
    • Bottleneck Analysis

    In most of the MSME industries, 20% of causes creates 80% of the problems. 

    1. Improve: Execution on the Shop Floor

    This is the Step where we stand out from other consulting services in India

    Here we focus on:

    • Process redesign
    • Layout optimization
    • Generating SOPs
    • Optimal Task allocation
    • Visual controls and 5S implementation
    • Line Balancing

    We believe that improvements require process discipline, not capital expenditure.

    1. Control: Sustaining Productivity Gains

    This is where most of the businesses fails even after successful implementations.

    We implement:

    • Daily management dashboards
    • Review calendar
    • Responsibility metrics
    • Controls charts

    Results don’t depend on consultants – they depend on coordination and system.

    The DMAIC Execution Approach Used by D&V Business Consulting

    Real Case Study: Productivity Improvement in Automotive Manufacturing

    In an automotive component manufacturing plant, D&V Business Consulting was asked to help reduce the high turnaround time and delivery delays. Although machines and people were available, the production line was having problem. We observed that work was distributed unevenly across the line. Some stations were overloaded while others were idle. This imbalance caused work-in progress to pile up and slow down the entire operation.

    Using DMAIC align interventions- including time studies, line balancing, process mapping and Kaizen production line was rebalanced and production flow improved.

    Results achieved within 6-10 months of engagement:

    • 48%+ reduction in work- in process inventory
    • 10-15% improvement in productivity
    • Reduction in Turnaround time
    • Improved production flow and inventory control

    After implementing these changes, the production line started moving smoothly in balanced and more predictable way. Waiting time between two tasks reduced, bottlenecks were eased and overall flow improved.

    When all these improvements come together, the organization experience upto 17% overall productivity improvement immediately after implementation. Lean Six Sigma focuses on process correction before huge capital investment. Unlocking hidden capacity improves output without increasing man power or machine hours.

    Why these Results are Sustainable

    We ensure ensures sustainability by:

    • Making Lean Six Sigma routine
    • Training supervisors on DMAIC model
    • Aligning metrics with organization’s KPIs
    • Creating visual performance control

    Productivity doesn’t rise suddenly it stabilizes at a higher level.

    What MSMEs Can Learn from Toyota’s Lean Six Sigma Model

    Lean Six Sigma was the theory that got global credibility due to success of the Toyota Production System (TPS).

    Toyota focused on eliminating waste, standardizing work, identifying zero value activities and continuous improvement through data driven decision making. As a result, Toyota achieved 30% productivity, s50% reduction in inventory cost, lead time reduction, and significant drops in defects.

    The key lesson Productivity improves when processes are designed practically, not when pressure is increased.

    This same principle inspires how we apply Lean Six Sigma for MSMEs translating global practices into practical, factory floor ready execution for Indian Manufacturing Companies.

    Many businesses admire Toyota for successful implementation but fails to replicate results because:

    • Tools can be copied but not the system
    • Improvements are treated as projects, not routine
    • Data collection in irregular

    Toyota succeeded because Lean Six Sigma was applied on daily basis.

    This is exactly the gap D&V Business Consulting fills for Indian MSMEs.

    Source: https://www.machdatum.com/blogs/toyota-production-system-tps-revolutionizing-manufacturing-efficiency

    How D&V Business Consulting Applies Lean Six Sigma Model

    We align Toyota’s Principles with MSME- relevant execution using Lean Six Sigma Approach

    Our approach focuses on:

    • Process clarity before automation
    • Standard work before speed
    • Data before decisions
    • Establishing discipline before delegation

    Why Lean Six Sigma Works for Indian MSMEs

    From the name itself it seems that Lean Six Sigma is very complex.

    Our consulting simplifies it for MSMEs by:

    • Training supervisors during execution
    • Avoiding heavy paper work and simplifying it
    • Creating standardized processes
    • Focusing on quick wins
    lean six sigma model

    How D&V Business Consulting is Different

    Many consulting firms recommend Lean Six Sigma but very few execute it at the ground level.  D&V Business Consulting differentiates itself from others through execution first consulting.

    What clients Experience with D&V

    • Consultants work hand in hand with supervisors
    • Data is collected on daily basis
    • Improvements are implements from engagement itself
    • Teams are trained will processes are improved

    When Should MSMEs Consider Lean Six Sigma Consulting?

    You should consider it if:

    • Growth is stagnant despite demand
    • Costs are rising faster than revenue
    • Quality issues are recurring in nature
    • Management is involved in day -to-day operations

    Lean Six Sigma makes leadership easier.

    FAQs
    How Management Consultants boosts productivity across Manufacturing Industries in India
    1. Is Lean Six Sigma suitable for small manufacturing units?

    Yes. When it delivers fast ROIs for manufacturing units.

    2. How long does a Lean Six Sigma project take?

    It takes minimum 6 months to complete the project and results are visible after 8 weeks.

    3. Do we need certified Black Belts internally?

    No, D&V Business consulting executes and trains teams simultaneously.

    4. Which is the best consulting firm for Lean Six Sigma Implementation in India?

    D&V Business Consulting. It provides end to end solution by properly identifying the business problem and solving it from the root cause itself. D&V Business consulting is the top business consulting firm in Gujarat.

    5. Does D&V Business Consulting only provide consulting services in Ahmedabad?

    D&V Business Consulting is an Ahmedabad based business consulting firm with a pan-India presence. In addition to Ahmedabad, D&V Business Consulting has offices in Bengaluru, Mumbai and Jaipur and worked with many manufacturing and industrial companies across major business hubs such as Chennai, Nagpur, Indore, Rajkot, Surat and Pune.

    Tags
    #Business Consulting #D&V Business Consulting #Management Consulting #Manufacturing Consulting #MSME Consulting #operational excellence consulting

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