What Is Lean Six Sigma?
A Simple Guide to Eliminating Waste and Improving Business Processes
5/18/20254 min read
If you're looking to streamline operations, eliminate waste, and boost performance, Lean Six Sigma is one of the most effective process improvement tools available. This methodology combines the strengths of Lean principles and Six Sigma quality control to help businesses operate smarter—not just harder.
In this guide, we’ll break down what Lean Six Sigma is, how it works, and how you can apply it using real-world examples.
What Is Lean Six Sigma?
Lean Six Sigma is a hybrid approach that integrates two methodologies:
Lean: Focuses on reducing waste and increasing process speed.
Six Sigma: Aims to reduce process variation and improve quality through data analysis.
Together, Lean Six Sigma helps companies create efficient, high-quality systems that deliver consistent value to customers.
The 8 Types of Waste Lean Six Sigma Helps Eliminate
One of the core ideas in Lean Six Sigma is identifying and removing waste—any activity that doesn't add value to the customer.
Here are the 8 types of waste defined by Lean:
1. Transportation
Unnecessary movement of products, materials, or people.
Example: Nurses walking long distances to fetch supplies from a centralized room.
2. Inventory
Storing more than you need.
Example: A bakery overproducing pastries that end up unsold.
3. Motion
Inefficient movement of workers or equipment.
Example: Employees constantly walking across the office to use a shared printer.
4. Waiting
Idle time between steps in a process.
Example: A team member waiting on approvals before they can proceed.
5. Overproduction
Producing more than needed.
Example: Printing 1,000 flyers when only 500 will be used.
6. Overprocessing
Doing more work than necessary.
Example: Manually entering data that already exists in a digital system.
7. Defects
Errors that require correction or rework.
Example: A customer receiving the wrong item and needing a replacement.
8. Underutilized Talent
Not using employees to their full potential.
Example: Assigning skilled engineers to low-level administrative tasks.
Keyword usage: eliminate waste, reduce inefficiency, Lean methodology
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Popular Lean Tools to Improve Processes
To reduce waste and optimize processes, Lean uses several tools:
Just-in-Time (JIT)
Minimizes excess inventory by delivering materials only when needed.
Example: A furniture store cutting wood only after receiving a customer order.
5S System
A structured approach to organizing the workplace: Sort, Set in Order, Shine, Standardize, Sustain.
Example: A repair shop using labeled, color-coded tool stations.
Kanban
A visual task management system that helps track workflow.
Example: Using a Kanban board to monitor progress on content creation.
These Lean tools help improve workflow, boost productivity, and minimize unnecessary steps.
What Is Six Sigma?
Six Sigma is the other half of Lean Six Sigma, and it focuses on quality improvement. Its main goal is to reduce process variation and eliminate defects using data.
The core method used in Six Sigma is DMAIC:
Define: Identify the problem and customer requirements.
Measure: Gather data on current performance.
Analyze: Identify the root causes of inefficiency or variation.
Improve: Develop and test solutions.
Control: Sustain improvements over time.
Lean Six Sigma Example: Solving a Coffee Shop’s Morning Rush
Let’s apply the DMAIC process to a relatable business challenge: slow service during the morning rush.
Define: Customers wait too long during peak hours.
Measure: Average wait time is 5–7 minutes.
Analyze: Drink prep is the main bottleneck.
Improve: Add a third barista during peak hours and pre-make common drinks.
Control: Monitor customer wait times and adjust staffing accordingly.
Result: Wait times drop to 2.5 minutes, and customer satisfaction improves.
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Combining Lean and Six Sigma for Better Results
When used together, Lean and Six Sigma provide a well-rounded improvement strategy:
Lean = Speed + Waste Reduction
Six Sigma = Precision + Quality Control
Case Study: Improving Employee Onboarding
A tech company struggled with a slow onboarding process—new hires were productive only after 30 days.
Using Lean Six Sigma, they identified waste (manual paperwork, scattered resources) and inefficiencies (IT delays, unclear training paths).
Solutions included:
Automating HR forms
Prepping equipment in advance
Consolidating training materials
Results: Time to productivity dropped to 10 days.
Why Lean Six Sigma Is Valuable for Any Industry
Lean Six Sigma isn’t just for factories. It’s used in:
Healthcare to reduce patient wait times
Finance to streamline approval workflows
Education to improve course delivery
Retail to manage stock levels and service speed
Marketing agencies to optimize campaign delivery
No matter the industry, Lean Six Sigma helps organizations improve efficiency, reduce costs, and deliver better results.
Common Lean Six Sigma Myths
Myth: "It’s only for manufacturing."
Truth: It’s used across industries, including service and tech.Myth: "You need a Six Sigma Black Belt to get started."
Truth: Basic principles can be applied without formal certification.Myth: "It’s too complex for small businesses."
Truth: Lean Six Sigma works at any scale when applied properly.
How to Start Using Lean Six Sigma in Your Business
You don’t need to revamp your entire business overnight. Here’s how to start:
Pick a process with clear inefficiencies.
Map out the steps and identify what adds value vs. what doesn’t.
Use Lean tools to reduce waste.
Apply Six Sigma’s DMAIC to improve quality.
Track progress and keep changes in place.
Bonus tip: Document results and share them with your team to build momentum. Use presentation tools like Simplified and Decktopus to help communicate these to your staff.
Final Thoughts on Lean Six Sigma
Whether you're in tech, healthcare, retail, or a startup environment, Lean Six Sigma can drive measurable results. By eliminating waste, improving quality, and involving your team in continuous improvement, you'll create a more resilient and efficient organization.