What is Lean Six Sigma?

Lean Autommotive Production Line

Welcome to our comprehensive guide on Lean Six Sigma! A transformative business methodology designed to improve your organisation's processes, reduce waste, and increase profitability. If you're looking to elevate your business operations to the next level, you've come to the right place.

What is Lean Six Sigma?

Lean Six Sigma is a synergistic blend of two powerful methodologies: Lean and Six Sigma.


Together, they provide a robust framework for improving efficiency, quality, and customer satisfaction.

What is Lean?

Lean focuses on eliminating waste and improving flow in the value stream. 


The 8 wastes are:


1. Defects

Defects refer to errors, mistakes, or imperfections in products or services that require correction. These defects lead to rework, increased costs, and delays.


2. Overproduction

Overproduction occurs when more products or services are produced than are actually needed. This leads to excess inventory, increased storage costs, and potential obsolescence.


3. Waiting

Waiting refers to idle time when resources such as employees, machines, or materials are not being utilised effectively. This can occur due to poor planning, imbalanced workloads, or inefficient processes.


4. Skills

This waste refers to not fully utilising the skills, talents, and abilities of employees. When employees are not engaged or empowered, their potential contribution to process improvement and problem-solving is wasted.


5. Transportation

Transportation waste occurs when materials, products, or information are moved unnecessarily between processes. This adds time and the potential for damage but does not add value to the product or service.


6. Inventory

Excess inventory ties up capital and takes up space. It can also lead to spoilage, obsolescence, and increased handling costs.


7. Motion

This waste involves unnecessary movements by employees or machines during the course of their work. Excessive motion can lead to inefficiencies, increased wear and tear, and even safety issues.


8. Over-Processing

Over-processing refers to any activity that doesn’t add value to the product or service from the customer’s perspective. This could be additional inspections, rework, or steps in a process that aren’t necessary.

What is Six Sigma?

Six Sigma is a measure of quality, it aims to reduce variation and defects in processes.  


Six Sigma is a data-driven methodology aimed at improving business processes by reducing defects and variations. Developed by Motorola in the 1980s, it uses statistical tools and techniques to identify the root causes of problems and implement sustainable solutions. The ultimate goal is to enhance the quality of products or services and increase customer satisfaction.


A Six Sigma process has a good throughput yield of 99.99966%

Lean: The Philosophy of Efficiency

Originating from the Toyota Production System, Lean is a methodology that aims to deliver value to the customer through optimised workflows and the elimination of waste. Waste can be anything from unnecessary steps in a process to redundant inventory.

Lean Manufacturing Production Line

Six Sigma: The Science of Quality

Developed by Motorola in the 1980s, Six Sigma is a data-driven approach focused on reducing defects and variation in processes. It uses statistical tools and techniques to identify the root causes of problems and implement sustainable solutions.


Lean Automotive Production Line
Lean Laboratory Production Line

Key Principles of Lean Six Sigma

  1. Customer-Centricity: The primary focus is to deliver value to the customer.
  2. Data-Driven Decision Making: Decisions are made based on data and statistical analysis.
  3. Continuous Improvement: The aim is to continually improve processes for better outcomes.
  4. Waste Elimination: Identifying and removing non-value-adding activities.
  5. Process Variation Reduction: Minimising inconsistencies in processes to improve quality.


The DMAIC Methodology

Lean Six Sigma projects often follow the DMAIC framework, which stands for:

  • Define

    Identify the problem and objectives

  • Measure

    Collect data to understand the current process.

  • Analyse

    Analyse: Investigate data to identify root causes

  • Improve

    Implement solutions to fix the issues

  • Control

    Maintain the improved process over time

Benefits of Implementing Lean Six Sigma


Cost Reduction: Lower operational costs through waste elimination.

Quality Improvement: Enhanced product or service quality.

Customer Satisfaction: Meet or exceed customer expectations.

Employee Engagement: Empower employees through skill development.


Benefits of Lean Six Sigma

How to Implement Lean Six Sigma


Executive Sponsorship: Gain support from all senior leadership.

Training: Educate the team on Lean Six Sigma principles.

Project Selection: Choose projects aligned with business goals.

Execution: Follow the DMAIC methodology.

Review: Monitor results and make necessary adjustments.

Lean Six Sigma is more than just a buzzword; it's a proven methodology for achieving business excellence. By understanding its principles and methodologies, you can unlock tremendous value for your organisation.

FAQs about Lean Six Sigma

  • Is Lean Six Sigma suitable for small (SME) businesses?

    Absolutely, Lean Six Sigma is scalable and can be applied to organisations of any size.

  • How long does it take to see results?

    The timeline can vary, but many organisations see improvements within a few weeks to months.

  • Is Lean better than Six Sigma?

    he question of whether Lean is better than Six Sigma isn't straightforward, as each methodology has its own strengths and is suited for different types of challenges. Lean excels at eliminating waste and improving process flow, making it ideal for organisations looking to become more efficient. Six Sigma, on the other hand, is focused on reducing defects and variations, making it suitable for improving the quality of outputs. Often, organisations find the most value in combining the two into Lean Six Sigma to take advantage of both methodologies.

  • Is Six Sigma the same as Lean Management?

    While both Six Sigma and Lean Management aim to improve business processes, they are not the same. Six Sigma is a data-driven approach focused on reducing defects and variations in processes. It uses statistical tools to identify and solve problems. Lean Management is more focused on eliminating waste and improving the flow of value to the customer. It emphasises simplifying and streamlining operations. Lean Six Sigma is a hybrid approach that combines the strengths of both.

  • What comes first, Lean or Six Sigma?

    The choice between starting with Lean or Six Sigma depends on the specific challenges your organisation is facing. If the primary issue is inefficiency and waste, then starting with Lean principles may be more beneficial. If the main concern is the quality of outputs and reducing defects, then Six Sigma could be the better starting point. Many organisations opt for a Lean Six Sigma approach, integrating both methodologies to address a broader range of issues.

  • Is Six Sigma Lean or Agile?

    Six Sigma, Lean, and Agile are distinct methodologies, each with its own set of principles and practices. Six Sigma focuses on reducing defects and variations through data-driven analysis. Lean aims to eliminate waste and improve process flow. Agile is a framework primarily used in software development that emphasises flexibility, collaboration, and customer-centricity. While Six Sigma and Lean are often combined into Lean Six Sigma, they can also be integrated with Agile principles to create a more flexible and adaptive process improvement approach.

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