Lean Six Sigma Consulting Services for Small to Midsized Manufacturers
Get the benefits of hiring a Lean Six Sigma consultant, without long-term overhead
Staying competitive in today’s manufacturing environment means controlling costs by continually seeking ways to improve quality and efficiency.
Lean Six Sigma gives you the proven methodology and toolset to achieve those goals, but keeping an in-house Lean Six Sigma consultant is often cost prohibitive for many small to midsized manufacturers.
That’s why so many organizations turn to Manex for Lean Six Sigma consulting services.
Manex is a leading California Lean Six Sigma consulting firm. For over 30 years, we’ve served California manufacturers as Lean Six Sigma consultants, bringing this game-changing methodology directly to shop floors.
By combining the efficiency of Lean methodologies with the power of data-driven Six Sigma analysis, we can reshape your business capabilities into highly optimized processes that reduce waste and maximize your profit margin.
Contact Manex today for an initial consultation, and let us show you how our Lean Six Sigma consulting services can increase your profitability.
What is Lean Six Sigma?
Lean Six Sigma is the powerful combination of two distinct methodologies, used by countless organizations worldwide to reduce waste, increase efficiency, and limit defects.
Together, these two methodologies give manufacturers a proven framework for improving their entire production flow, helping them stay competitive and profitable.
How Lean and Six Sigma Work Together
Lean and Six Sigma are powerful tools on their own, but when paired together, they significantly address the operational challenges that every manufacturer faces.
Lean methodology directly addresses speed and efficiency through:
- Identifying and eliminating waste
- Analyzing and streamlining production layouts
- Reducing unnecessary movement and improving cycle time
Six Sigma brings improvement to quality and consistency by:
- Collecting and measuring process performance data
- Identifying the root causes of defects and variation
- Implementing controls to sustain improvements
Lean focuses on waste reduction, while Six Sigma uses data and statistical analysis to reduce variation. Together, they help companies reduce costs, improve quality, and deliver the greatest value to their clients.
The Benefits of Hiring a Lean Six Sigma Consultant
While virtually any organization can benefit by introducing Lean Six Sigma methodologies to their workplace, the cost of hiring a full-time specialist to implement and maintain these programs is significant..
Keeping an in-house specialist requires paying a full-time salary and benefits. On top of that, their usage is naturally limited during downtime between improvement initiatives.
Conversely, working with a Lean Six Sigma consulting firm like Manex eliminates the cost burden of a full-time position, while ensuring you still get professional Lean Six Sigma implementation strategy.
Our certified Lean Six Sigma consultants:
Manex’s Lean Six Sigma consulting services give you the leadership and benefits of a professional, strategic Lean Six Sigma implementation strategy, without the overhead of a permanent on-staff position.
Ready to start seeing the benefits of Lean Six Sigma in your organization? Talk to a Manex consultant today.
Talk to Our Expert.
What Our Certified Lean Six Sigma Consultants Bring to the Table
At Manex, our certified Lean Six Sigma consultants focus on optimizing operations through measurable, real-world improvement.
We can help you:
- Unlock measurable financial impact by identifying inefficiencies that drive unnecessary cost and constrain capacity
- Reduce avoidable costs by eliminating waste and defects that erode margins and increase rework
- Increase operational capacity by improving throughput and shortening cycle times—often without additional capital investment
- Improve cash flow and working capital by optimizing inventory management practices—reducing excess inventory, freeing up cash, and lowering carrying costs without compromising service levels
- Stabilize and scale performance through standardized workflows that improve quality, productivity, and training efficiency
- Strengthen decision-making by embedding data-driven insights that support profitability, risk reduction, and strategic growth
Our Lean Six Sigma implementation strategy includes designing and leading Lean Six Sigma projects that tackle your biggest challenges, delivering rapid results.
Lean Six Sigma consulting services we offer include:
- Value Stream Mapping
- 5S System
- Kaizen (continuous improvement) exercises
- Statistical Process Control (SPC)
- Poka-Yoke (mistake proofing)
- Problem Solving with Root Cause Analysis
- Just-In-Time production
- Kanban Systems
- Measurement System Analysis (MSA)
- Total Productive Maintenance
These proven techniques are applied strategically by our Lean Six Sigma consultants to meet your operational goals. They have been used by countless organizations to increase efficiency, reduce waste, and build sustainable systems that deliver ongoing value.
Manex Success Stories
As a Lean Six Sigma consultant for California manufacturers, Manex has helped our clients make dramatic improvements to their operations, significantly increasing quality and efficiency.
Below are some examples of the success our clients have seen with help from Manex’s Lean Six Sigma consulting services:
Client Business Need
A leader in the specialty surgical table and patient positioning markets, Mizuho-OSI experienced increased demand for their products, which created pressure to meet cost, quality, and delivery objectives. They needed help revising their approach to manufacturing in order to meet demand.
Results Delivered
Using Lean manufacturing techniques, Manex implemented a value stream mapping process to identify areas for improvement. Our team created a current state map, and developed a future state map, as well as an implementation road map to reach the company’s objectives. We also implemented several Kaizen activities focused on reducing cost and improving on-time delivery.
The results delivered reduced costs, improved layout, and improved bottom line, including:
- Reduced direct labor content (38.8 hours to 32.7 hours) = 15.7% improvement
- Reduced lead time (3.5 weeks to 9 hours) = 93% improvement
- Reduced WIP from $940K to $260K = 73% improvement
- Increased Trios Base productivity = 10.3% improvement
- Increased Trios Tops productivity = 49% improvement
Client Business Need
Advanced Material Solutions (AMS) was struggling with material shortages and excessive defects in supplier parts, causing them to fall far short of their production goals. To make matters worse, profitability was also suffering from poor management of Purchase Price Variance (PPV).
Results Delivered
Manex’s Lean Six Sigma consultants developed and deployed a five-week program, implementing reengineered processes that eliminated parts and assembly receiving problems while improving the PPV process flow with a systematic approach.
With the implementation of the improved supply chain processes, AMS was able to dramatically increase profitability and improve productivity. Specific results include:
- 90% on-time delivery improvement
- 66% PPV Flow improvement
- 20% sales increase
- $500,000 inventory reduction
- $150,000 labor cost savings
Client Business Need
Ahead of the move to a new facility, precision metals and plastics machine shop Wilkinson Manufacturing wanted to reimagine their layout. Manex’s Lean Six Sigma consulting services were able to identify and implement operations process improvements for the new facility, creating a more functional layout with room for growth.
Results Delivered
Manex Lean Six Sigma consultants for manufacturing optimized Wilkinson’s flow and work cell layout in the new facility, implemented 5S to organize the new workplace, improved consistency of operations, as well as productivity and yield, and provided a foundational understanding and initial implementation of lean manufacturing.
Specific results include:
- Improved collaboration across the manufacturing team
- 30% improvement in throughput from $2.2 million to $2.6 million
- 20% reduction in labor costs
- Workforce development improvements of $44,000
Begin Planning Your Lean Six Sigma Implementation Strategy With Manex
Since 1995, Manex has helped California manufacturers eliminate inefficiencies, reduce waste, and increase quality with Lean Six Sigma consulting services. We serve manufacturers across a wide range of industries including:
- Aerospace and defense
- Food and beverage
- Electrical
- Computer and electronics
- Machinery manufacturing
- Metal and plastic fabrication
- And more