The relationship between Lean and 6 Sigma – The interaction between the two types of improvement tools (Part 1)

In the manufacturing sector, there has been much debate about the difference between Lean and 6 Sigma and comparing their effectiveness. Most experts believe that lean is a mathematical improvement tool more than 6 Sigma, especially when evaluating the method of applying this type of tool.

However, in recent times, comparing Lean with 6 Sigma is not making much sense, as many large organizations have started to combine the application of both tools at the same time to create high efficiency. than. On the other hand, the only difference between the two types of tools is in the implementation process to achieve the final goal, while their ultimate goal is to reduce waste in production.

To better understand the difference between Lean and 6 Sigma, we need to look at their origin.

Lean originated from an innovative idea of ​​Henry Ford and later, applied to Toyota’s production system. The group has developed a new manufacturing process that reduces the time it takes to reset equipment whenever a change is needed. Since then, lean has been widely adopted by many large businesses around the globe.

Six Sigma was developed at the same time as Lean but introduced by Toyota for the first time in the United States. Motorola’s Bill Smith designed the Six Sigma tool to measure product defects and improve overall quality. The original idea was further developed by GE manufacturing corporation. The surprising efficiency of Six Sigma has become the driving force for many other businesses to follow suit.

History is an important part of the discussion of Lean and Six Sigma because it shows a clear picture of the ideas and ways of how each method can improve production efficiency. Lean has so far been constantly demonstrating its role in ensuring the production process is lean and not wasteful. Six Sigma approaches it from a different perspective. This tool evaluates current processes to find the point of waste both in production and outside of production, thereby providing solutions to limit waste. The basic goal of Six Sigma is to eliminate defects, which is to limit the waste in the manufacturing process. Lean meanwhile, Lean’s focus is to cut out unnecessary steps and ensure only essential steps are taken. This also means eliminating potential wasteful factors before production is carried out.

As with predictive maintenance, actions taken in advance to prevent incidents are always less expensive than dealing with the consequences after the incident. Lean has been supported by more experts for the same reason. However 6 Sigma also has its own specific advantages. Six Sigma plays an important role in any strategic vision. When businesses use a mission statement and conduct SWOT analysis, 6 sigma helps you focus on areas of improvement. On the other hand, there is no contradiction to the parallel application of both tools at the enterprise. So it can be said that under the current competitive pressure, the discussion about whether to apply lean or 6 Sigma is being directed by manufacturers on how to integrate them?

Productivity and Quality Office