Six Sigma vs. Lean: What Are the Differences?

What is the difference between Six Sigma vs. Lean?

If you’re starting a new business or looking to improve the efficiency of your existing operations, it’s good to learn about these two helpful methodologies. Both are profitable and designed to improve the quality of your product or  service.

However, there are notable differences between them as well. If you apply either of them but don’t know them fully well, your new venture can fall flat on its face.

In this piece, we will discuss what Six Sigma and Lean are, the things that make them unique from each other, and how they can benefit your business. Read on.

What Is Six Sigma? 

Six Sigma is a process that relies on statistics and data analysis to lower manufacturing defects to a maximum of 3.4 per million units or events. It is also an approach that provides organizational tools to help in managing a business.

Understanding Six Sigma, we know that by enhancing performance and minimizing process variation, defects or errors can be reduced.

As a result, employee morale and product or service quality improve, ultimately leading to higher profitability for the business.  

What Is Lean? 

Lean, also known as lean manufacturing, refers to the use of Lean practices, principles, and tools in the production of physical products. The goal is to avoid waste, improve processes, reduce expenses, encourage innovation, and limit marketing time in a highly competitive and ever-evolving international marketplace.

Many people think of lean manufacturing as the goal itself of eradicating waste, but the true end of this approach is to provide sustainably high-quality products to customers.   

In reaching that goal, Lean defines waste as anything that does not contribute to the value that a customer receives by using the product or service. This can be anything, from an activity to an object. If it does not increase the satisfaction of the customer, it is considered waste.

The Lean principle considers many things waste, including too much inventory, idle time, and inefficient processes, among others.

Lean also operates on a systematic approach for waste reduction that does not deviate from set control parameters like quality and quality. 

Six Sigma vs. Lean 

There are many differences between Six Sigma and Lean manufacturing, but the most important distinction is that Six Sigma is a quality control method that focuses on reducing defects, while Lean is a production system that emphasizes eliminating waste. 

Both methods are important tools for improving manufacturing efficiency, but they take different approaches. As any Six Sigma guide will tell you, this approach uses statistical analysis to identify and correct errors in the manufacturing process, while Lean relies on a continuous improvement cycle to identify and eliminate wastes of time, money, and resources. 

Both methods can be adapted to fit the needs of any manufacturing operation, but it is important to understand the differences between the two before deciding which one to implement.

Which Is Right for Your Business?

Whether you choose Lean or Six Sigma will have a considerable effect on every area of your business. Companies usually have a hard time choosing between the two approaches as each one of them offers its own benefits and unique effects on business operations. 

Before deciding which one is the right approach for your organization, there are a few things you need to consider. 

First off, what are the specific goals and needs of your business? Every enterprise is unique, so neither Lean nor Six Sigma can be used in the same manner, even among organizations within the same industry. 

In any case, it is often wise to do some research to know how competitors are working to achieve their goals.

The Lean Six Sigma Hybrid

There is a consensus among modern experts that combining Lean and Six Sigma can be the most effective approach. If you were ever confused about what is Lean Six Sigma, you shouldn’t be.

Lean Six Sigma is simply the fusion of both methodologies, and using it allows you to maximize flexibility. Lean can be used to eliminate waste and optimize a process. To limit variance and enhance performance, Six Sigma can be applied.  

The key is to balance the two, which can be a tricky process. According to some experts, Six Sigma applications can only be productive with the cleansing effect of Lean.

Others choose between the two based on certain “custom formulas” that they have created and found success with in their organization.

Therefore, when choosing between Six Sigma and Lean, it’s important to look not only into the present goals you have for your company but rather into the future ones too.

And don’t forget to factor in the uniqueness of your business, which should require a unique approach as well. That goes for whether you decide on Lean, Six Sigma, or a mix of both. 

Getting to the Core 

Overall, Six Sigma vs. Lean is a matter of getting the best of each individual approach and combining them to produce a powerful impact on your business.

The key is to truly understand the unique aspects of your organization and how this hybrid approach can thoroughly address each need.

It may take some trial and error or experimentation, but the more customized your final approach is, the more effective it’s going to be. 

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