How do you choose between Lean Six Sigma and Kaizen for improving manufacturing cycle times?

All answers to this question.

In my fifteen years of quality management, I’ve found that Kaizen is your "low-hanging fruit" tool. If the root cause of the delay is obvious—like poor workstation layout—a 3-day Kaizen event is perfect. However, if your cycle time variation is high and you don't know why, you need the statistical rigor of Six Sigma. Use the Define and Measure phases to see if the problem is "noise" or a specific process shift. Don't use a sledgehammer (DMAIC) if a scalpel (Kaizen) will fix the immediate bottleneck.

   Answered 2024-04-13 by Deborah Sullivan

Have you mapped out the Value Stream yet? Sometimes seeing the non-value-added time visualized makes the choice between a quick fix and a long-term project much easier.

   Answered 2024-04-14 by Raymond Fletcher

• Raymond, we actually finished the VSM last week. It showed that 40% of our lead time is just waiting for QA sign-off. Because the bottleneck involves cross-departmental approvals and not just manual labor, I’m starting to think a Green Belt project might be necessary to overhaul the digital approval workflow.

     Commented 2024-04-15 by Douglas Harrison

Start with Kaizen to build momentum. If the improvements don't stick after two months, then pivot to a full Lean Six Sigma project to address the deeper systemic issues.

   Answered 2024-04-16 by Cynthia Miller

• Great advice, Cynthia. Building that "culture of improvement" with small Kaizen wins first makes the team much more receptive when you bring out the heavy statistical charts later.

     Commented 2024-04-17 by Deborah Sullivan