What is the difference between Lean and Six Sigma and how do they work together?

All answers to this question.

Think of it this way: Lean is about "Speed and Flow" by removing waste (Muda), while Six Sigma is about "Precision and Accuracy" by reducing variation. Lean looks at the entire value stream to remove non-value-added steps. Six Sigma uses statistical tools to ensure that the value-added steps are performed consistently every time. In a modern "Lean Six Sigma" approach, you use Lean to clean up the process first—because there is no point in using Six Sigma to make a wasteful process more consistent. Combined, they create a fast, efficient, and highly reliable workflow.

   Answered 2024-01-18 by Nancy Peterson

When you look at your current operations, do you see more issues with "slowness and bottlenecks" or with "errors and inconsistent output quality"?

   Answered 2024-01-24 by Paul Henderson

• Paul, we definitely see both, but the slowness is what our customers complain about most. Following Nancy's advice, it seems we should prioritize Lean tools like 5S and Standardized Work to get our house in order first. Once we have a standard process that isn't bogged down by excess inventory and waiting, we can then apply Six Sigma tools like Control Charts to make sure our output doesn't deviate from the customer's specifications.

     Commented 2024-01-30 by Cynthia Adams

Lean is the "What" and Six Sigma is the "How much." Lean identifies the problem areas in the flow, and Six Sigma quantifies the improvements needed.

   Answered 2024-02-05 by Ronald Davis

• That’s a very concise way to put it, Ronald. They are truly two sides of the same coin when it comes to achieving operational excellence.

     Commented 2024-02-12 by Nancy Peterson