Medical Device Manufacturer Leverages Green Belt Training for almost $1M in total benefits
A medical device manufacturer was interested in boosting the skills of their manufacturing support team members, and improving their processes to address financial constraints. They chose to conduct two waves of Green Belt training at the same time (2 groups of 10 people). The on-site training was launched in November 2025 and finished in March 2026. Projects were completed by the end of June 2026.
6 project teams were selected (3-4 people each) that were tasked with reducing downtime and material variance.
One project had exceptional results, resulting in over $500K in additional revenue (hard savings) for the facility, and the other 5 projects resulted in over $400K in soft savings.
On average, each project on average was validated for about $195,000 per project per person, with a median savings of $61,000 per project per project (more typical outcome). This resulted in a total impact of over $970,000!
The investment cost into the training was between $2000-3000 per person for a class of 20 people. Each student’s time commitment was 48 hours of training, coaching sessions with us (about 5 hours per person), plus the time to work on the project with their team (approximately 4 hours per week for about 3 months after training was completed, or about 36 hours per person). That equates to a total of 90 hours of their time (or about 2 full weeks). The project sponsors were also very engaged and helped coach the project teams in between our coaching sessions.
The return on investment has been less than one month (at least 10:1 return), which makes this an easy decision on whether to enroll in future programs. In addition, the skills they learned in the program will be leveraged on all future projects and activities for that employee (leading to even more benefits). We also got feedback from the project sponsors that they saw a noticeable improvement in communication and team building amogst the project team members.
Here are the impressive results:
| Class | # Trained | # Projects Completed* | Annual Benefits | Avg per Project |
| Nov 2025 – Mar 2026 | 20 (19 certified, 1 left company) | 6 (3-4 people per project) | $970,000 ($520K in hard savings, $470K in soft savings) | $195,000 ($10,000 per person, median per project = $61,000) |
If you’d like to have us help you with a similar program conducted virtually or locally in South Florida (where we provide the Master Black Belt support of the projects if you don’t have it), please check out our Lean Six Sigma Coaching Program for Organizations >>>
If you want something specific, then fill out the quote form and we can create a custom quote for your company, and help you achieve a similar return on investment.
