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This study describes a procedure that applies the Lean Six-Sigma approach to reducing the production costs of a Portuguese bolts manufacturer. The project was proposed by the product’s customer, who suggested improving some parameters of the processes associated with its manufacture. The customer’s expectations and requirements are called ‘Voice Of the Customer’ (VOC) focusing on the reduction of production costs. Bolts manufacturing has some particularities, such as the considerable lot-size and the high level of products produced. Some of the important Six-Sigma and Lean tools are discussed, which will be of help to Six-Sigma practitioners. The empirical study illustrates methods used to Define, Measure, Analyse, Improve and Control (DMAIC) the Six-Sigma approach. This study consolidates the efficiency and the excellence of the DMAIC methodology, providing arguments to demonstrate its …