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Lean vs Six Sigma

Lean:

✓ Originated from Toyota 

✓ The Toyota Production System (TPS) is at the heart of Lean 

✓ The Lean methodology focuses on eliminating waste and smoothing the process flow 

✓ Lean is not about cutting costs. It is about removing waste without sacrificing quality


Waste is whatever slows the delivery process down

  • Reworking
  • Doing things customer doesn't want
  • Piles of materials not being worked on
  • Customers Queuing

Six Sigma:

 ✓ Developed by Motorola 

✓ To improve processes by reducing variation and defects 

✓ Many (but not all) of the tools are statistical in nature and 6 Sigma emphasises taking action based on fact rather than opinion or common belief 

✓ The ‘Sigma’ (σ) rating of a process can be used as an indicator of how many defective parts a process produces 

✓ 6 Sigma equates to 3.4 defects for each million opportunities (DPMO)





How they complements each other?


Key Principles:

General Topics:

How to make customer happy? (Voice of Customer - VOC)

1) Minimum variation

2) Quick delivery (Short Lead Time)

3) Reasonable Cost


 Six Sigma Belts:


The role of yellow belt:

✓ Understands the terminology and overall Lean 6 Sigma process 

✓ Is aware of the major tools and techniques embraced by Lean 6 Sigma 

✓ Understands the underlying philosophy of Lean and 6 Sigma 

✓ Acts as a team member under the direction of a Green Belt or Black Belt



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