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Six Sigma and Lean, Both Are Same Philosophy or Different?

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Viewing 11 posts - 1 through 11 (of 11 total)
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  • #54589

    Yuvraj Hedaoo
    Participant

    Integration of Lean and Six sigma definitely impacts on bottom line of the organisation. There are numerous articles, papers and blogs available to get this information.
    Six sigma methodology improves quality of product and services which is helpful in increasing top line. Adoption of lean concept in manufacturing process leads to reduction in wastes, results increase in bottom line by reduction manufacturing cost.
    As I understand, Six Sigma focuses on reduction in variation in process by using statistical method/technique whereas lean concept emphasizes on eliminating the wastage by leveraging tools such as kaizen, 5S, Heijunka (Level Scheduling).

    How can we integrate lean tools in six sigma project? At what stage? If we can use lean tool in six sigma project then why it is not lean manufacturing?
    Can someone share views/experience?

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    #196221

    MBBinWI
    Participant

    @Yuvraj-Hedaoo – Lean should come first. It is about reducing waste, one of which is losses in production due to product that has excessive variation. Use Six Sigma to attack that excessive variation. This is a simple explanation as whole books have been written on this topic.
    You have forgotten (or maybe don’t even know) about Theory of Constraints (TOC). Use that methodology to identify the constraint in the system – only by improving the constraint will improvement efforts actually manifest themselves in improved throughput.

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    #196225

    Brian Cooper
    Guest

    Just to piggy-back on MBBinWI ….Lean is and should be a business philosophy. At Toyota it is the way they do business. It is integrated in their DNA. From 5S, to waste to JIT and small batch processing Lean uses the team and their process expertise to improve all aspects of operations. Lean builds the skills of the workforce and teaches everyone from the company President to the hourly line worker to look for better processes. Six Sigma uses mathematics and statistics that seem alien to most hourly workers.Both are powerful and when brought together can change the blood of the organization. Stand-alone, I would say that Lean is a cultural change and Six Sigma is more of an intitiative.

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    #196227

    Fahd lahrech
    Guest

    Lean is about flow of product through the value chain in the shortest lead time possible by eliminating waste. Six sigma is about moving the mean to the target and reducing variation. Lean is a philosophy, six sigma is a methodology, lean is horizontal view of the value stream whereas six aigma is the top vertical view of the value stream. Lean attacks no only waste which muda but also mura and muri which is variation, so six sigma is a good part of how to become lean but not the only piece for the lean puzzle.

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    #196228

    Yuvraj Hedaoo
    Participant

    Thanks Brain for sharing your view.
    Currently I am working on six sigma project. we are using statistical method and lean tools to optimize the process. so I was uncertain about application of lean tools.

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    #196229

    Don Strayer
    Guest

    I’ve found the incorporation of lean tools into six sigma (lean six sigma) problematic. Same goes for incorporation of theory of constraints (6ToC). For continual process improvement it makes a lot more sense to start with Lean, add ToC to optimize the process, then add six sigma to address remaining quality problems. If you have an obvious quality problem apply six sigma right away.

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    #196231

    SCILSS
    Guest

    There’s a truth in all the anwers you have received. Mainly due to the fact that not one single problem is the same.
    Six Sigma techniques and tools require a (although maybe bad but) stable process and if that’s not the case you should first try to reach this state by removing excess Special Cause variation which can in many cases be done with applying Lean tools. In many Lean “games” you find that using Lean tools not only reduces the “waste” of waiting overproduction etc., but also defect due to the more focussed production methods/environment

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    #196232

    Yuvraj Hedaoo
    Participant

    Thanks SCILSS and Don.
    process is normal.

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    #196710

    BMGI India
    Participant

    Six Sigma and Lean both are different theories, formulated to improve the the process engineering and other activity results covering numbers of threads allied to production, marketing, sales, market analysis and management. Six Sigma theory is concerned more to needs of customers and businesses while lean is focused more upon production.

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    #196711

    Chris Seider
    Participant

    I don’t agree @BMGIIndia1

    The best continuous improvement knows how to meld the tools of six sigma and lean. However, there isn’t as much distance between the tool sets as some would like others to believe.

    The tools are quite complementary.

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    #196712

    MBBinWI
    Participant

    @BMGIIndia1 – Wow, I hope for your colleagues’ sake that’s not the level of competence in your organization.

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