LEAN SIX SIGMA

The Lean Six Sigma methodology allows to combine the intrinsic benefits of the two methodologies:

- Lean Production: focused on eliminating waste and optimizing resources in production processes. It essentially focuses on creating value with as little work as possible. It is a management philosophy that derives above all from Toyota and its Toyota Production System (TPS), renowned for its ongoing commitment to eliminate the seven wastes identified by Taichi Ohno.

Six Sigma: focused on the variability and reduction of process defects, it consists of a quality management program based on the control of the standard deviation that aims to bring the quality of a product or service to a level of absolute excellence (admitted no more than 3, 4 defective parts per million). First introduced by Motorola in the second half of the 1980s, it spread to other major companies, such as General Electric, Toyota, Honeywell and Microsoft.

An effective adoption of the Lean Six Sigma methodology is able to guarantee on the one hand the improvement of the quality of products or services, eliminating production defects and keeping under control the problems related to the standard deviation of the processes (6 ơ), from the other the waste reduction, the optimization of resources and the creation of value for the customer, in addition to maintaining the level of quality achieved, thanks to the concept of continuous improvement (Kaizen).

The implementation of the Lean Six Sigma methodology involves the application of the five DMAIC phases, which Cesap reviewed in the Digital DMAIC methodology in the Industry 4.0 era:

THE MAIN BENEFITS OF THE LEAN SIX SIGMA METHODOLOGY

Thanks to the combined application of principles and tools belonging to the two methodologies, Lean and Six Sigma, there are many advantages for the company in terms of increased productivity and profitability. Statistically, the economic benefits for companies that correctly adopt the Lean Six Sigma methodology can be evaluated in at least 2-3% of the turnover value, with peaks over 10%.

Below are just some of the most recurring benefits deriving from the effective application of the methodology:

Increased product quality: aspect directly perceived by the customer
Customer service improvement: aspect directly perceived by the customer
Product cost reduction: possibility of greater margins and / or price reduction
Increase in process efficiency: definition and application of new operating standards with consequent optimization of work flows
Greater involvement and participation of staff: general improvement of working conditions with consequent increase in satisfaction and productivity of operating personnel.
Competitive advantage: reducing the cost per product brings a potential advantage over the competition

HOW TO ACQUIRE THE SKILLS ON LEAN SIX SIGMA METHODOLOGY:
CERTIFICATION LEVELS

In order to correctly adopt the Lean Six Sigma methodology it’s necessary first of all to acquire adequate knowledge of the principles and tools and subsequently to know how to concretely apply what has been learned in one’s own company: it is therefore advantageous to choose training courses on the Lean Six Sigma methodology in which the integration with simulations, practical exercises and management of business projects.

In fact, this type of training approach allows for greater involvement and the possibility of applying what has been learned about these methodologies, with the supervision and support of tutors, practically right from the training phase.

Lean Six Sigma training is organized according to a model inspired by Six Sigma one; in fact, there are different levels of certification that involve the acquisition of specific skills, characterized by the following denominations: white / yellow / green / black / master black / executive master black belt.

In order to materialize the training on the Lean Six Sigma methodology in an effective project of change and improvement, a declared sponsorship by the company management and a wide involvement of the organization are required.