DMAIC

Lean Six Sigma & Process Optimization

Cut the Waste.
Keep the Output.

Black Belt-credentialed process improvement for manufacturers, distributors, and healthcare employers. We apply rigorous DMAIC methodology to eliminate the waste, variation, and inefficiency that is quietly eroding your operational performance — and your bottom line.

Start with a Free Process Audit
D
Define
M
Measure
A
Analyze
I
Improve
C
Control

Valhar's process improvement practice is led by a credentialed Lean Six Sigma Black Belt with 20+ years of applied experience across healthcare manufacturing, tissue banking, pharmaceutical distribution, and regulated logistics — not a consultant who learned it in a classroom.

Lean Six Sigma Black BeltCSCPMHA20+ Years Applied

What We Do

Process Improvement Services

Every engagement begins with data, not assumptions. We apply the right tool to the right problem — then transfer the capability to your team so the gains hold.

01

DMAIC Project Leadership

Full-cycle facilitation of Define → Measure → Analyze → Improve → Control projects. We lead, your team learns. Outcomes are measured in dollars, cycle time, and defect rate — not activities.

Root Cause AnalysisStatistical AnalysisControl Plans
02

Value Stream Mapping

Current-state mapping to identify non-value-added steps, bottlenecks, handoff failures, and inventory waste. Future-state design with a prioritized improvement roadmap your team can execute.

Current-State MapFuture-State DesignWaste ID
03

FMEA — Failure Mode & Effects Analysis

Systematic risk identification for processes, products, and compliance workflows. Prioritized by severity, occurrence, and detectability — with corrective action plans tied directly to operational outcomes.

Risk PrioritizationCorrective ActionsCompliance
04

Kaizen Facilitation

Structured 3–5 day rapid improvement events targeting a specific process. Cross-functional teams. Measurable outcomes. Sustained change. Kaizen events are the fastest way to demonstrate ROI on a process improvement investment.

Rapid ImprovementTeam FacilitationQuick Wins
05

KPI Design & Performance Dashboard Build

If you can't measure it, you can't manage it. We design leading and lagging indicator systems tied to your business objectives — absenteeism, throughput, quality, compliance, and cost — and build the reporting infrastructure to track them.

Leading IndicatorsDashboard DesignReporting
06

Operational Turnaround Support

When performance has deteriorated and leadership needs answers fast — diagnostic assessment, root cause identification, and a 90-day improvement plan with embedded execution support. Lean tools applied at speed.

Diagnostic Assessment90-Day PlanEmbedded Support

Methodology

How DMAIC Works in Practice

DMAIC is not a consulting framework — it's a disciplined problem-solving structure that prevents organizations from jumping to solutions before they understand the actual problem. Here's what each phase produces.

D
Define

Define the Problem, Scope, and Success Criteria

We establish a project charter with a clear problem statement, measurable goal, defined scope, and business case. Stakeholders align before work begins — not after. This phase prevents the most common process improvement failure: solving the wrong problem.

Project CharterSIPOCVoice of CustomerStakeholder Map
M
Measure

Establish Baseline Performance with Data

We collect current-state data on the process — cycle times, defect rates, absenteeism numbers, throughput, cost, or compliance metrics depending on the engagement. A validated measurement system is established so everyone agrees on what's being tracked and why.

Data Collection PlanProcess CapabilityMeasurement System AnalysisControl Charts
A
Analyze

Identify Root Causes — Not Symptoms

This is where most improvement efforts fail — they treat symptoms. We use structured analysis tools to trace variation and defects back to their true root causes. The result is a prioritized list of causes verified by data, not opinion.

Fishbone / Ishikawa5-Why AnalysisPareto ChartsRegression AnalysisValue Stream Mapping
I
Improve

Design and Test Solutions That Address Root Causes

Solutions are generated, evaluated, piloted, and refined before full implementation. We use structured decision tools to select improvements with the best ROI. Changes are piloted at small scale first to validate impact before organization-wide rollout.

Solution MatrixPilot DesignFailure Proofing (Poka-Yoke)Standard Work
C
Control

Lock In the Gains — Permanently

The hardest part of process improvement isn't the improvement — it's making it stick. We build control plans, updated SOPs, training documentation, and monitoring systems that ensure gains are sustained after the engagement ends. Your team leaves capable, not dependent.

Control PlanUpdated SOPsTraining TransferStatistical Process ControlResponse Plan

Industries

Where We've Applied Lean Six Sigma

Our practitioner experience spans regulated, high-stakes environments where process failures have real operational and compliance consequences — not just efficiency losses.

Healthcare Manufacturing

FDA-regulated, quality-critical production environments
🧬

Tissue Banking & Biotech

Sterile processing, chain-of-custody, AATB compliance
💊

Pharmaceutical Distribution

DSCSA compliance, cold chain, inventory accuracy
🏭

Industrial Manufacturing

Throughput, OEE, changeover time, defect rate reduction
📦

Distribution & Logistics

Order accuracy, pick/pack efficiency, carrier performance
🏥

Hospital Systems & Rural Health

Patient flow, staffing utilization, workforce health operations

What to Expect

Typical Engagement Outcomes

Results vary by industry, baseline performance, and engagement scope. These ranges reflect outcomes from applied Lean Six Sigma engagements in healthcare, manufacturing, and distribution environments.

15–40%
Reduction in process cycle time
Across manufacturing, distribution, and healthcare administrative processes
20–60%
Defect / error rate reduction
Sustained through control plans and updated standard work
3–6×
Return on engagement investment
Measured against fully-loaded engagement cost within 12 months
90 days
Kaizen results visible
Rapid improvement events produce measurable outcomes within one quarter

Past Employer Outcomes

What This Work Looks Like in Practice

The following outcomes represent results achieved in prior operational leadership roles across healthcare, manufacturing, tissue banking, and distribution environments. All cases are anonymized per standard consulting practice.

Healthcare Manufacturing · 1,000+ Employees

Absenteeism Reduction Through Workforce Health Infrastructure

A national healthcare manufacturer faced chronic absenteeism rates significantly above industry benchmarks, creating production gaps, overtime cost, and compliance risk. Systematic workforce health and scheduling interventions — including root cause analysis of absence patterns, return-to-work protocols, and supervisor training — reduced facility-level absenteeism and improved scheduling predictability across multiple shifts.

↓ Absenteeism
Measurable facility-level reduction
↑ Scheduling
Improved production predictability
National Distribution · Multi-Site · Supply Chain

Supply Chain Operations Turnaround Across Regional Distribution Centers

A national distribution company operating across multiple regional DCs faced escalating cost-per-order and declining fill rates. Operational redesign — including inventory positioning, process standardization, and carrier performance management — reduced distribution costs and improved order accuracy. Cross-functional team restructuring established sustainable performance management infrastructure.

↓ Cost/Order
Multi-site cost reduction
↑ Fill Rate
Order accuracy improvement
Tissue Banking · FDA-Regulated · Biotech

Lean Process Implementation in FDA-Regulated Manufacturing Environment

A tissue banking and biotech manufacturer required process improvement without compromising FDA regulatory compliance. Lean Six Sigma methodology — including value stream mapping, FMEA, and Kaizen events — identified non-value-added steps in sterile processing workflows. Throughput metrics improved while maintaining full AATB accreditation and regulatory compliance documentation standards.

↑ Throughput
Compliant process improvement
✓ Compliance
FDA & AATB standards maintained
Multi-Site Healthcare Operations · FMLA · OSHA · ADA

Workforce Compliance Infrastructure Across Regulated Multi-Site Operations

A multi-site healthcare employer faced significant compliance exposure across OSHA recordkeeping, FMLA administration, and ADA accommodation workflows — with inconsistent practices across locations. Compliance programs were designed and implemented site-by-site, with supervisor training, standardized documentation, and a return-to-work protocol that reduced legal exposure and improved workforce continuity.

↓ Exposure
OSHA / FMLA / ADA risk reduced
✓ Standard
Consistent multi-site protocols
Healthcare Genomics · Operations Build · Regulated Environment

Operations Infrastructure Build for High-Growth Genomics Organization

A rapidly growing genomics and clinical diagnostics company needed operations infrastructure scaled to match its growth trajectory without proportional headcount increases. Process design, staffing model development, and KPI systems were built from the ground up — including workforce planning frameworks, performance review structures, and quality management processes supporting CLIA-regulated laboratory operations.

↑ Scalability
Infrastructure built for growth
✓ CLIA
Regulatory quality standards met
Evidence-Based Practice · Ongoing Research

Research-Backed Methods — Not Just Experience

Valhar's founder is completing a Doctor of Business Administration at Belhaven University, with doctoral research focused on measuring the operational and financial impact of preventive workforce health interventions on employer absenteeism and productivity. Our methods are built on both 20+ years of applied experience and ongoing academic rigor.

MHA · DBA (in progress) · CSCP · LSSBB
Belhaven University · Expected 2028

All outcomes above reflect results achieved in prior employer roles. Organizations and individuals are not identified per standard consulting confidentiality practice. Specific metrics, percentages, and dollar figures are available upon request during client discovery conversations.

How to Engage

Engagement Options

We structure engagements to match your timeline, budget, and organizational readiness. Every option includes a project charter, stakeholder alignment, and documented deliverables.

Rapid Assessment

Process Diagnostic

A focused 2–3 day assessment of a specific process or operational pain point. Deliverable: a written diagnostic report with prioritized findings and a recommended improvement roadmap.

From $4,500 · Fixed scope
Event-Based

Kaizen Workshop

3–5 day structured rapid improvement event targeting one process. Cross-functional team facilitation, root cause analysis, solution piloting, and a 30-day control plan built before the event closes.

From $9,500 · Fixed scope
Full Project

DMAIC Engagement

Full Define through Control cycle, typically 8–16 weeks. Embedded Black Belt project leadership, team coaching, statistical analysis, pilot implementation, and complete control documentation.

From $24,500 · Scoped to project
Ongoing Advisory

LSS Retainer

Monthly advisory support for organizations running multiple improvement initiatives or building an internal Lean capability. Includes project reviews, coaching, and on-call consultation.

$2,500/month · 3-month minimum

Ready to find out what your process waste is actually costing you?

We start every engagement with a free 30-minute process diagnostic conversation. No obligation — just clarity.