Lean Six Sigma: Optimize processes, eliminate waste

After the pitfalls of 90-90 rule Having illuminated and Sigma have already dealt with rules in metrology, we are turning to a methodology that aims to systematically combat inefficiencies:

Lean six sigma. This combined methodology combines the principles of Lean manufacturing and Six Sigma, to optimize processes, eliminate waste and improve quality.

The basics: Lean Management meets Six Sigma

Lean: The fight against waste

Lean focuses on eliminating waste (‘Muda’ in Japanese, the method originally comes from Toyota) and maximising customer benefit. It's about doing more with less by identifying and removing activities that don't add value. The eight types of waste are often combined with the acronym ‘DOWNTIME’:

• Defects: Products that are unusable or require rework
• Over-production: Products that are manufactured in excess or too early
• Waiting: Delay in process steps, on material or permits
• Non-used talent: Waste of human potential and abilities
• Transportation: Unnecessary movement of materials, products and people
• Inventory: Do not process surplus products and materials
• motion: Unnecessary or inefficient movements of employees and materials
• Extra-processing: More work than necessary to complete a task

Six Sigma: Perfection through data

Six Sigma, on the other hand, is a data-driven approach that aims to reduce process variations and minimize errors, with the goal of achieving near-perfect performance of no more than 3.4 errors per million opportunities. This is equivalent to Six-Sigma, or 6σ. A Six Sigma process with 3.4 ppm thus has an accuracy of 99.99966%, which means that 99,99966% the products or services are error-free. It uses statistical methods to identify and eliminate the causes of defects. Let's take a closer look at this:

The Power of Combination

Together, Lean Six Sigma provides a powerful, unified framework to improve efficiency, reduce waste, and minimize errors. The core principles include:

1. Customer focus

Maximum value delivery according to customer needs and requirements is the focus of all activities.

2. Value stream analysis

Identify all process steps to identify value creation and waste and optimize the entire flow.

3. Waste disposal

Remove non-value-adding steps to improve flow and make the most of resources.

4. Team communication

Clearly communicate new standards and practices and provide training to take all stakeholders with you.

5. Culture of Change

Promote a data-driven culture that welcomes continuous improvement and flexibility.

The DMAIC cycle: Systematic to success

The core methodology of Lean Six Sigma is the DMAIC cycle:

Define

Clearly outline the problem, customer needs and project goals. This is where the foundation for the entire improvement process is laid.

Measure

Collect data to quantify the current state of the process and identify deviations. No improvement without measurement.

Analyze (analyze)

Analyze the collected data to uncover the root causes of inefficiencies or defects. This shows the power of statistical analysis.

Improve (improve)

Develop and implement solutions to address the identified issues. Creativity meets systematics.

Control (control)

Establish mechanisms to monitor and maintain the improvements achieved in the long term. Sustainability is the key.

Practical examples: When theory meets reality

Automotive industry: Eliminate test errors

A car manufacturer used Six Sigma to identify and eliminate the causes of electrical test errors in production. The objective: The test error rate per vehicle by 50% to reduce. Through systematic data analysis and process optimization, this ambitious goal was not only achieved, but even exceeded.

Production: Lean workshops in practice

In a production company, waste was identified and eliminated with the help of lean workshops and employee involvement. The work content could be optimally distributed, the cycle times of the workstations adapted to the customer's schedule and thus the quantities increased to the desired level.

General Electric: The pioneer

Companies like General Electric have successfully used the Lean Six Sigma process to improve processes and reduce costs. GE is considered one of the pioneers and shows how the method can be successfully applied in various areas, from production to the service sector to quality management.

Lean Six Sigma in Software Development

In software development, Lean Six Sigma can improve quality by reducing defects and process variations. It increases efficiency by eliminating waste and streamlining workflows. Particularly interesting is the compatibility with modern approaches such as Agile, Lean Startup or Design Thinking. Especially in innovation processes, companies benefit from the structure and data orientation that Lean Six Sigma offers, while other approaches ensure flexibility and creativity.

The Pareto principle: The 80/20 lever

Lean Six Sigma is closely linked to the Pareto principle (80/20 rule) as it helps identify the ‘few but crucial’ causes that cause most of the problems. By concentrating on these 20% The causes can be found in teams of 80.% solve the problems and thus achieve the greatest benefit with the least effort.

The Level 92 philosophy: Good enough is good enough

However, the ‘Level 92’ philosophy does not find strong allies in Six Sigma alone. Lean, on the other hand, is our friend: By eliminating waste and reducing variation, one can achieve a ‘good enough’ product or solution more efficiently without getting lost in the ‘other 90 percent’ of the 90-90 rule. It's about designing processes to deliver core value while making the most of resources, which fits perfectly with the idea of completing projects at ‘Level 92’ as successful.

Why Lean Six Sigma 2025 is more relevant than ever

In today’s digital age, the basic requirements of Lean Six Sigma – minimising waste and reducing variation – are more important than ever. Companies are under enormous pressure to optimize their processes, reduce costs and at the same time increase quality standards. The methodological combination of both approaches enables companies to assert themselves against competitors in the long term and to operate successfully even in economically difficult times.

Best practices for successful implementation

1. Anchoring philosophy

The successful implementation requires a consistent anchoring of the Lean Six Sigma philosophy in the company. Professionals and managers must not only understand the methods, but also live the principles of continuous improvement and data-based decision-making.

2. Employee involvement

The involvement of employees is crucial. Those who work with the processes on a daily basis often know the hidden inefficiencies best.

3. Continuous learning

Lean Six Sigma is not a one-off project, but a journey of continuous improvement. Regular training and certifications keep the knowledge up-to-date.

4. Governance and monitoring

As an entrepreneur, you should focus your attention on the risks. These must be minimized and errors eliminated as completely as possible. Governance across all areas of the company must be ensured by quality managers at all times.

Conclusion: The Road to Operational Excellence

Lean Six Sigma provides a proven framework for strategically optimizing processes, reducing costs and sustainably increasing quality standards. It is far from outdated – it remains a tried-and-tested, versatile method that can be combined not only with traditional approaches, but also with modern methodologies such as agile or design thinking.

The combination of Lean principles and Six Sigma methodology creates a powerful synergy: While Lean makes sure we do the right things, Six Sigma makes sure we do those things right. In a world where efficiency and quality determine success or failure, Lean Six Sigma is not just a useful tool – it is a crucial competitive advantage.

Only companies that always keep an eye on their entire business processes and systematically optimize them can cope with the challenges of the modern market. Lean Six Sigma provides the right framework for this: Structured, data-based and geared towards sustainable success.