What is
Lean Six Sigma?
Lean Six Sigma is a process improvement methodology that combines Lean thinking, which focuses on removing waste, with Six Sigma, which focuses on reducing variation and defects. It uses data, teamwork and a structured DMAIC framework to make processes faster, more consistent and more cost-effective.
If you have ever worked in a business that feels busy but not truly productive, you have already seen the kinds of problems Lean Six Sigma was designed to fix. The approach gives you a practical way to see what is really happening in your processes, remove the steps that do not add value and tackle the root causes of errors and delays.
On this page we will explain what Lean Six Sigma is in simple terms, how it works in practice, the key principles and tools involved and how organisations of all sizes are using it to improve quality, reduce cost and free up capacity.
What Is Lean Six Sigma in Simple Terms?
Lean Six Sigma often gets dressed up in jargon: DMAICs, Kaizens, Black Belts. It can sound like something only academics or engineers would care about. But at its heart, it’s just common sense.
Think about making a cup of tea. If you boil the kettle three times, overfill the mug, and spill milk on the counter, you’ve wasted time, energy, and resources.
- Lean is about getting rid of that waste
- Six Sigma is about making sure the process goes right every time.
That’s it. No jargon. Just a smarter way of working.
Lean is about speeding things up by removing waste – the stuff that slows you down or adds no value. Think of it as “doing things quickly and efficiently”.
Six Sigma is about doing things right – reducing variation and defects by using data and problem-solving techniques.
When you combine the two, you get Lean Six Sigma – a powerful approach that focuses on improving quality, speed, and cost all at the same time.
Why Does Lean Six Sigma Work?
Lean Six Sigma works because it focuses on two of the biggest headaches in any business: waste and variation. By tackling these, you can increase productivity, improve customer satisfaction, and reduce costs, without overloading your team.
The Key Principles
Focus on the customer
Deliver what they actually value.
Identify and remove waste
Anything that doesn’t add value is out.
Reduce variation
Make processes predictable and reliable.
Use data, not guesswork or opinions
Base decisions on proven facts and analysis.
Empower your people
Improvement is a team sport.
Where Did Lean Six Sigma Come From?
- Lean roots come from within the Toyota Production System and its focus on flow and waste removal
- Six Sigma was developed at Motorola in the 1980s to reduce defects through statistics.
- Lean Six Sigma as the later integration of both.
Who Uses Lean Six Sigma?
From Toyota and Motorola to the NHS and small local businesses, Lean Six Sigma is used worldwide in sectors like manufacturing, finance, healthcare, logistics, and beyond. At VA Innovation, we’ve helped everyone from heritage sites to financial services firms embed these principles and see real results.
What Are the Benefits of Lean Six Sigma?
- Lower costs by cutting waste and rework
- Faster lead times and smoother flow
- Better quality and fewer errors
- Higher customer satisfaction and retention
- More engaged employees working on improvement
- Data-led decision-making instead of guesswork
Lean Six Sigma Belt Levels
Training and certification are often structured into “belt” levels:
- White Belt– Basic awareness.
- Yellow Belt – Team member understanding.
- Green Belt– Project leader with problem-solving skills.
- Black Belt– Advanced problem-solver and coach.
- Master Black Belt – Strategic leader and mentor.
Find out more details from our Lean Six Sigma Training and Certification page
Lean vs Six Sigma vs Lean Six Sigma
| Lean | Six Sigma | Lean Six Sigma | |
|---|---|---|---|
| Main Focus | Flow and speed. Remove wasted steps and delays. | Quality and consistency. Reduce variation and defects. | Both flow and quality. Improve speed while also reducing errors and variation. |
| Primary goal | Deliver value faster with fewer resources. | Achieve stable, predictable processes with low defects. | Deliver reliable, fast and cost effective processes that customers trust. |
| Typical problems it tackles | Long lead times, bottlenecks, too much work in progress, unnecessary movement or complexity. | High error rates, rework, customer complaints, output that is not consistent. | Processes that are both slow and error prone or where improvements in one area create problems in another. |
| Typical tools | Value stream mapping, 5S, visual management, standard work, Kanban, flow and pull systems. | Uses statistical analysis and more detailed data to understand variation. | A blended toolkit that uses Lean to find and remove waste and Six Sigma tools to analyse data and control variation. |
| Use of data | Uses simple data and visual measures to show flow and spot waste. | Uses statistical analysis and more detailed data to understand variation. | Uses the right level of data for the problem, from simple visuals to deeper statistical analysis. |
| Best suited for | Improving speed, flow and productivity in processes that are cluttered or overcomplicated. | Improving quality and reducing defects where errors are costly or risky. | Cross functional improvements where you need both faster flow and more reliable outcomes. |
How VA Innovation Can Help
We don’t just teach Lean Six Sigma – we make it work for your business. Our consultancy blends expert training, real-world project delivery, and a practical, no-nonsense approach. You’ll get the tools, mindset, and support to make sustainable improvements and measurable gains.
FAQs About Lean Six Sigma
What is Lean Six Sigma in simple terms?
It’s a way of improving your processes so you can work faster, cheaper, and better – by removing waste and reducing errors.
Is Lean Six Sigma only for manufacturing?
No – it’s used in healthcare, finance, services, government, and more. Any process can be improved.
Do I need to be good at maths to use Six Sigma?
No – while data is important, most tools are straightforward, and training covers what you need.
How long does it take to see results?
Some changes deliver quick wins in weeks; bigger projects can take months. The key is to start small and build momentum.
What’s the difference between Lean and Six Sigma?
Lean focuses on speed and waste elimination; Six Sigma focuses on quality and variation reduction. Together, they’re stronger.
Do I need a certification to use Lean Six Sigma?
No, but training can help you apply the methods effectively and lead projects with confidence.
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