Eighteen Months Kindle Edition by Leslie Jones McCloud (Author) Format: Kindle Edition

Six Sigma Success Stories: Driving Excellence Across Industries

DMAIC
Six Sigma, a data-driven methodology for process improvement, has revolutionized businesses worldwide since its inception at Motorola. By minimizing defects and variability, it delivers substantial financial and operational benefits. 

Pioneered by Motorola with a remarkable 94% defect reduction in core processes, Six Sigma gained global prominence through General Electric’s (GE) implementation under CEO Jack Welch, yielding over $2 billion in annual benefits by 1999. This established it as a benchmark for excellence.

At 3M, Six Sigma extended beyond manufacturing to environmental sustainability. Training over 55,000 employees across all belt levels prevented 2.6 million pounds of pollutants and saved more than $1 billion. Remarkably, they achieved a 61% reduction in volatile air emissions, surpassing their 25% goal, proving its applicability to green initiatives. 

An illustration of the 8 wastes in Lean Six Sigma, highlighting 3M’s approach to efficiency and sustainability.

Dow Chemical leveraged Six Sigma for safety, reducing ergonomic and motor vehicle injuries with a 30% drop in vehicle accidents in targeted units, showcasing versatility in operational excellence.

In pharmaceuticals, Catalent Pharma Solutions applied statistical controls to their Zydis line, averting two batch losses worth $50,000 in just two weeks, demonstrating rapid ROI.

Catalent’s Founding and Ownership History

•  2000: Cardinal Health acquires R.P. Scherer Corporation, a pioneer in softgel and oral technologies, forming the foundation of what would become Catalent’s core capabilities.

•  2006–2007: Cardinal Health restructures its pharmaceutical services arm (including Scherer’s operations) into “Cardinal Health Pharmaceutical Technologies and Services” (PTS).

•  February 2007: The Blackstone Group acquires Cardinal Health PTS for approximately $3.4 billion in cash.

•  June 2007: The acquired entity officially launches as Catalent Pharma Solutions, an independent company focused on drug delivery, manufacturing, and packaging. Headquartered in Somerset, New Jersey, it quickly grew through acquisitions like Aptuit (2012) and Micron Technologies (2014).

•  Later Milestones: Catalent went public in 2014 (NYSE: CTLT), expanded into biologics and gene therapies, and was fully acquired by Novo Holdings (parent of Novo Nordisk) in February 2024 for $16.5 billion, delisting it from public markets. This deal emphasized its role in scaling production for GLP-1 drugs like Ozempic.

Exxon Mobil boosted refinery energy efficiency, achieving a 17% return on capital employed and lower costs, illustrating impact in heavy industry.

These cases underscore Six Sigma’s adaptability, from sustainability to safety and efficiency, inspiring ongoing adoption. 


Jack Welch and the evolution of Six Sigma at General Electric.

Financial Snapshot of Six Sigma Success Companies (Q3 2025)

As of October 31, 2025, these companies showcase varied financial health based on their latest quarterly earnings. Here’s a breakdown:

**3M (MMM) – Strong Momentum

3M delivered robust Q3 results: GAAP sales $6.5B (up 3.5% YoY), adjusted EPS $2.16 (up 12%, beat estimates), and organic growth of 1.5%. 0 2 Operating margins hit 22.2% (up 130 bps). Full-year guidance raised to $7.95–$8.05 adjusted EPS. YTD stock return: +30%, near all-time highs – thriving post-restructuring. 43

**Dow Inc. (DOW) – Resilient Amid Headwinds

Q3 net sales $10B (down 8% YoY) due to segment weakness, but EBITDA improved to $868M QoQ. 35 GAAP EPS $0.08; operating loss -$0.19 – beat loss expectations via cost cuts. 41 Q4 sales outlook $9.4B (below consensus). Challenging chemicals market, but positioning for recovery.

**Catalent Pharma Solutions – Private & Stable

Acquired by Novo Holdings for $16.5B in Feb 2024, delisted from NYSE (no public trading/financials). 18 Pre-acquisition Q1 FY2025 revenue $1.02B (up 4%). Now integrated into Novo’s portfolio, focused on GLP-1 growth – financially secure under private ownership.

**ExxonMobil (XOM) – Energy Powerhouse

Q3 earnings $7.5B (down 12% YoY), adj. EPS $1.88 (beat $1.82); revenue $85.3B (missed slightly). 9 12 Record production (4.8Moebd), cash flow $14.8B, dividend hike. Resilient despite oil volatility.

**GE Aerospace (GE) – Soaring High

Q3 revenue $11.3B (up 26% YoY), adj. EPS $1.66 (beat by 14%), operating profit $2.3B (up 26%). 27 29 Raised FY profit guide to $8.45–$8.65B. Aviation boom drives exceptional performance.

Switched in April 2024, GE is a classic case of a conglomerate streamlining into high-tech specialization. General Electric (GE) started as a broad industrial giant in 1892, but over decades, it divested non-core businesses to sharpen its edge. 

    In June 2016, GE sold its appliance division to China’s Haier for $5.4 billion. The business (now GE Appliances, a Haier subsidiary) kept its Louisville HQ, U.S. manufacturing, and GE branding (licensed until 2056). It’s still a top U.S. player, investing $3 billion+ in American operations since the sale. 


Overall: Most are solid – GE & 3M excelling, Exxon steady, Dow navigating challenges, Catalent bolstered by acquisition. Six Sigma legacy endures in efficient operations!




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