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Lean Six Sigma in Tobacco Industry

As per the industry classification benchmark, this industry sector includes the following subsectors –

Tobacco – Manufacturers and distributors of cigarettes, cigars and other tobacco products. Includes tobacco plantations.

  • A global leader in undergarments manufacturing found that it had highest rejections coming from causes like heat transfer labels, stains and skip stitches. A DMAIC project led to reduction in rejections by more than 50% and millions of dollars in savings. Rejection levels were brought down from 3% to 1.5% within 4 months.
  • PU footwear rejection was resulting in INR 7.5 million losses per year. The critical defects were contamination, side bubbles, overlaps and marks. By use of statistical techniques, it was found that temperature control, mixing sequence and cleaning were found to be critical X’s at process level. DoE was carried out with temperature and mixing sequence combinations to generate the best possible combination that minimizes rejections. The project led to big competitive advantage for the footwear manufacturer.

Feedback from participants


A superbly presented training program, which not only talks about six sigma but also about its applications and useful related tools.
-Abhijit Roy Sarkar, ITC.

I liked the quality management and the process of the training.
– Yogesh Pendharkar, Manager, ITC.

I liked the course material and above all, Vishwadeep who taught us giving real life examples. If you want to achieve confidence level in your professional life, then this is the right platform.
– Nikhil Jain, Admin, ITC.