Six Sigma Vs Lean Sigma

Introduction

Quality and consistency witness six Sigma, whereas efficiency, defines Lean Sigma. No compromise in quality standards of products and services day-after-day takes place in six Sigma. It gives you a certain level of quality. Still, with lean Sigma, the case is that it concentrates on how functioning procedures are designed and controlled to minimize inadequacies that can be ascribed to delays, errors, and waste. Each approach has the ability in dramatic enhancement; using both ways simultaneously can give recognition and rectification of the issues at the primary level utilizing the most suitable toolkits. Here is one example of it; reaching an aim of zero record needs a decrease in bunch sizes and connecting of several programs by utilizing lean, which also hints at minimizing procedure fluctuation by using six sigma methods. 

Now, we will come to both six Sigma and lean Sigma separately.

Six Sigma

Six Sigma goes for people-oriented procedures and systems to upgrade quality stability. It is a well-organized, disciplined, data-proceeding mode to remove defects in any procedure – production to transactional and outcome to service. The two engineers, Bill Smith and Mikel J Harry, working at Motorola in 1986, first developed this approach. Six Sigma focuses on one goal: to bring down defect figures in any procedure. It utilizes one of the two approaches – DMAIC (Define, Measure, Analyse, Improve, and Control) or DMADV (Define, Measure, Analyse, Design, and Verify). Six Sigma adopts both processing speed and quality to adapt to modern technology and demands. It is the removal of errors or defects that can hinder delivering exclusive services. It also aims to modify the procedure to put a boundary before the procedure variations to 3.4 errors or defects per million.

Lean Sigma

Lean Sigma witnesses the removal of waste and speeds up the procedure. The lean system has eight kinds of waste: waiting, overage, modification, movement, over-clarifying, catalogue, intelligence, and unwanted. It aims to decrease the procedure disparity, the outcome of which is a speedy cycle of duplication improvements. Under lean Sigma, there are various lean tools used.

1. Clarify procedures – Once the procedures turn out to be compound, we would need a hugely trained task force to make the activities of those procedures. Thus, lean tools can clarify or simplify the procedures as much as possible.
2. Improve speeds – Speed plays the most vital role for a customer. If a speed element directly connects with customer contentment.
3. Enhance flows – The product flow needs to be smooth-running during the manufacturing phase; else, it could lead to gridlock, increased inactive or slothful time, or much more than that. Thus, lean tools helps to enhance flows within our procedures.
4. Shrink checklist – Checklists condemn aspects of a provided procedure. More extensive checklists lead to higher real estate costs, which also witnesses raw material depreciation and so much more. A smaller level of checklists goes to a halt in manufacture due to the inconvenience of raw materials when needed.
5. VSM (Value Stream Mapping) – It helps detect procedural wastes and the reasons behind these wastes.
6. Kaizen – It aims to concentrate on little-little improvements. It includes the dedication of low-level folks towards procedure enhancements, made easier by subordinates and encouraged and supported by management.
7. In time – It goes according to the customer’s wish to meet the customer’s demands and desires as when it comes from the customer’s side.
8. SMED (Single Minute Exchange of Dies) enhances impediments during the changeover period. It goes with the principle of decreasing changeover time to within ten minutes.
9. Poka-yoke – The device used for operating on defects, errors or failures.
10. Jidoka – The assembly or production line automatically ends if there is an error, defect or failure.
11. Heijunka – It is a conceptual part that defines line balancing. It focuses on distributing the workload by balancing production channels.
12. Gemba (Go and See) – Things you need to focus on under this are to observe the procedure and accomplishment in real-time, then those observations need to be recorded.
13. Kanban – Ongoing inventory level on a real-time basis needs to be presented and handled by kanban boards.

Let us have a look at six Sigma vs Lean Sigma

The program defines six Sigma, whereas philosophy explains lean Sigma. Regulatory culture alternate is not attempted by six Sigma, while lean sigma attempts at re-regulating the culture and etiquette among the workers. Six sigma business tactics and philosophy revolve around the notion that companies can add up to gain a competitive edge by decreasing errors in their manufacturing and mercantile procedures. At the same time, lean Sigma aims at improving speed. Six Sigma has a more extended graph, whereas lean has a shorter graph.

The primary medium in a six sigma is the data, while the primary medium in a lean sigma is the demand. Six Sigma can improve the cost of poor quality, and lean Sigma determines to improve operating costs. Six Sigma utilizes various operational improvements, while lean Sigma generally utilizes value stream surveys. Six sigma project has a length of 2 to 6 months, while the lean sigma project has a length of 1 week to 3 months. Six Sigma decreases variation and is of higher complexity, whereas lean Sigma decreases waste and are of moderate complexity.

Six Sigma will remove errors, but it will not hinder optimizing procedure flow. At the same time, the lean sigma concept does not include the utilization of advanced analytics benchmarks needed to evaluate and compress the procedure’s abilities so that they become ‘lean’ in the truest sense possible.

Six Sigma focuses on making ‘black-belts’ while lean Sigma is usually make-do with very little or no training at all. Although both the Sigma uses tactile learning, lean is suitable for the manufacturing part while six Sigma is suitable for any business procedure. Lean Sigma is dependent on differences between the best execution of plans and the current. 

Mistake-proof procedures 

Lean is efficiently used to decrease or remove mistakes or errors in given procedures. It has the following attributes: 

1. Quality hindrances.
2. Excessive differences.
3. Composite issues.
4. Challenging rootstock causes recognition.
5. Several technical contemplations.

In the above cases, six sigma tools should be preferred for:

1. Minimize differences.
2. Apply scientific analytics.
3. Use robust project lease.
4. Concentration on quality hindrances.
5. Employ technical procedures.

A combination of both sets of issues by the most decision-making identification. Fitting lean six Sigma in the middle of this continuance reflects a more interdependent and comprehensive approach. It is alright that a particular issue needs only lean or six sigma tools. Lean Six Sigma is a moderately new pattern giving a more comprehensive selection of approaches. A growing number of operations (procedures, system, hospitals, services, municipalities, military, insurance, etc.) have been uniting their work into a lean six sigma approach. The system of these fusions is very broadly. The most efficient approaches are as follows: 

1. Management direction and participation.
2. A crew of trained specialists.
3. Utilization of teamwork.
4. An acceptable and understandable problem-solving procedure.
5. Some channels or systems to apply proper tools.

Choosing the right certification

The certification varies according to any company’s guidelines, and there are a few uncertainties regarding the parity of certification:

1. The right authorization body – You need to look at if the certification body is identified by leading worldwide companies and bodies. Two central authorization bodies are identified worldwide: the American Society for Quality (ASQ) and International Association for Six Sigma Qualification (IASSC).

       2. The proper extent of certification – out of four levels of certification, you need to check out which certification is well-suited for you. You have to go through the preconditions and capability for each certification before going for the right one for you. 

While assessing a training and certification organization, some of the facets which need to be considered are as follows: 

1. Accreditation – An organization accredited by the ASQ or IASSC should be chosen over anything else. The track has the accreditation, and it is all upon you which one you would go for; either six sigma or lean six sigma. The proper accreditation and, consequently, the right accredited training partner will give you the best way of training with the high standards of the accrediting body.
2. Medium of delivery – You should not hurry while choosing an organization. You should go according to your needs and offer various delivery options. It would help if you looked at what is suitable for you and the best way to go. All offer options that have the flexibility to choose the best fit according to your desire. Professionals go for instructor-led online training over any other options as it gives you the best of flexibility.
3. Duration – You should search for flexibility in the duration of the training. You must hardly take one or two days for completion or finalization of some contracted courses, while others might take straight four to five days. You should choose the most suitable one according to your ability or parity of preparation and experience.

Eligibilities for certification, examinations, duties and responsibilities

For six Sigma, there are certain things you get along with: criteria for eligibility, examination procedures, and availability of jobs for certified professionals. 

For Six sigma green belt (CSSGB) certification:  

Eligibility:

You need a minimum of three years of full-time experience in more than one field in the CSSGB figure of knowledge.

Examination –  

1. Written, multiple-choice examination managed by ASQ.
2. The duration of the examination is four hours long.
3. One hundred questions are given.
4. Language – English. For some of the programs, language availability – Spanish, Mandarin, and Portuguese.
5. Exams are brought via PBT (paper-based testing).
6. Made available at ASQ-sponsored sites.

Roles and responsibilities that would be suitable for you – 

1. Assistance with data collection.
2. Analysis for black belt projects.
3. Lead green belt projects or teams.

Recertification –  

CSSGB has lifetime access and does not need recertification. 

For six sigma black belt (CSSBB) certification:

Eligibility:

You should be done with two projects with signed affirmation and a minimum of three years of work experience in more than one field of the six sigma belt figure of knowledge. 

Examination – 

1. Written form conducted by ASQ.
2. One hundred fifty questions are given.
3. The duration of the examination is four-hour long.

Roles and responsibilities that would be suitable for you – 

1. Lead problem-solving projects.
2. Train and coach teams.

Recertification –

CSSBB has a validity of three years from the actual date of certification. Either you can document 18 RU credits or give the examination again for renewal. 

For six sigma master black belt (MBB) certification: 

Eligibility: You need to either have a current ASQ certification in six sigma black belt (CSSBB) or have five years of experience in the field of a six sigma belt or master black belt or finalization of 10 six sigma black belt projects. Participants must have these qualifications at least to have their portfolio reviewed. 

Portfolio review – 

Participants must have these qualifications at least to have their portfolio reviewed. A review panel estimates participants’ SSBB and MBB work. To give the MBB examination for the participants, the panel should agree to the portfolio. 

Examination – 

1. Multiple-choice questions.
2. One hundred questions are given.
3. A performance-based assessment needs to be done.
4. To agree to and respond to context materials.

Conclusion

You are confused about whether to go for six Sigma or lean Sigma? It is all about your departmental practice and which place or field you feel will be perfect for enhancing your organization’s procedure. Last but not the least, go for a lean six sigma course if you are glancing between learning both the Sigma.

          If efficiency alone is a factor, the lean six Sigma works excellent. Its omission stays with the point that it needs the management to spend many attempts and time training their individuals and having full-time LSS trainers at hand endlessly. It is presumed that the effectiveness of their reach will repay the attempts.

That is where the stumbling block knocks. Candidate projects for the approach, dependent on their “Return On Investment” (ROI), are typically prioritized by an organization that utilizes lean six Sigma. The outcome of which the ones with the best ROI are set about in the first place. With each passing time and since the trainers have taken responsibility and are on duty, the application cost remains unconverted. An ROI lesser than recurring lean six sigma application costs will be noticed in the projects. However, expenses have reached rock bottom.

For example, for making driveshafts, steel or machinery, Lean six Sigma helps organizations reduce expenses by making the procedures more effective and efficient. It cannot happen to be available without any cost, but you will have the approach at the lowest possible cost with lean Sigma. Note that if you are almost close to that minimum cost, you should think again and again before taking up lean six Sigma. 

          Lean Sigma is undoubtedly the best way for effectiveness to be considered, but no way cures for all indispositions exist. It has no solutions for the issues such as collaborative branding, lack of calculated observation or internal organization politics. Lean Six Sigma is bound to happen to be a draining concept with lowering payback.

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