• SREEKA CHANDRAN
• Dr. Maqbool Khan

Lean Six Sigma (LSS) has become an important operational excellence methodology for Indian manufacturing organisations because it combines the waste elimination principles of Lean with the variation and defect reduction principles of Six Sigma. Indian manufacturing industries operate under considerable pressure to improve product quality, reduce defects, control production costs and increase process efficiency. However, the effectiveness of Lean Six Sigma may differ across manufacturing sectors because of differences in production volume, process complexity, product variety, regulatory requirements, technology and organisational capabilities. The present study comparatively examines the effectiveness of Lean Six Sigma across selected Indian manufacturing sectors with particular emphasis on quality improvement, defect reduction, cost reduction and process efficiency. The study is based on secondary evidence obtained from published empirical studies and industrial case studies involving automobile and automotive components, textile and apparel, food processing, and other Indian manufacturing organisations. The comparative analysis indicates that Lean Six Sigma has produced measurable improvements across the selected sectors. Automobile and automotive-component studies report substantial reductions in DPMO and defects, while textile and apparel studies demonstrate improvements in defect rates, sigma levels and financial savings. Food-processing applications demonstrate LSS’s usefulness in reducing overfilling, rework and process variation. The evidence also indicates that LSS benefits o depend strongly on management commitment, employee involvement, data availability, process standardisation and the ability to sustain improvements. The study concludes that Lean Six Sigma is broadly effective in Indian manufacturing, but its impact is sector-specific and should be evaluated using a combination of quality, defect, cost and process-efficiency indicators rather than a single performance measure.

Lean Six Sigma, Indian manufacturing, quality improvement, defect reduction, cost reduction, process efficiency, DMAIC, manufacturing sector.

"SECTOR-WISE EFFECTIVENESS OF LEAN SIX SIGMA IN INDIAN MANUFACTURING: A COMPARATIVE ANALYSIS OF QUALITY, DEFECTS, COST AND PROCESS EFFICIENCY", International Journal of Emerging Technologies and Innovative Research (www.jetir.org), ISSN:2349-5162, Vol.13, Issue 10, page no.a762-a770, October-2026, Available :http://www.jetir.org/papers/JETIR2610083.pdf

"SECTOR-WISE EFFECTIVENESS OF LEAN SIX SIGMA IN INDIAN MANUFACTURING: A COMPARATIVE ANALYSIS OF QUALITY, DEFECTS, COST AND PROCESS EFFICIENCY", International Journal of Emerging Technologies and Innovative Research (www.jetir.org | UGC and issn Approved), ISSN:2349-5162, Vol.13, Issue 10, page no. ppa762-a770, October-2026, Available at : http://www.jetir.org/papers/JETIR2610083.pdf