Lean Six Sigma – Is it an Oxymoron?

      During a conversation with a colleague this week, we got into a discussion around a favorite topic, lean six sigma.  Both of us received our initial training when it was just called six sigma.  Lean tools were briefly mentioned in the body of knowledge.  The formal addition of ‘lean’ came about in the early to mid-2000s.  The conversation eventually lead to the point where we tossed around the question of do the two belong together?

       At a certain level one could argue they do not.  Lean looks to improve efficiency with a laser focus on optimizing processes to reduce or eliminate waste.  Steps of the process or processes are examined for either value-added and non-value added activities.  Other concepts include pull systems, value stream mapping, Kaizen events, and 5S (sort, set in order, shine, standardize, and sustain).

      Six sigma seeks to improve effectiveness of processes with an intense focus to determine, meet and satisfy the needs of customers.  A strong underlying philosophy is that if one puts customer needs to the front of the line, the net results will improve the bottom line.  There are frameworks such as DMAIC and DMADV, each with a plethora of tools we all know very well.

      So is there a conflict here?  I’ve seen and I’m sure you have also the definition of efficiency as doing things right and effectiveness as doing the right things.  I’ve seen situations where too intense focus on efficiency ended up producing a product or service customers perceived as cheapened and stopped their purchases.  I’ve also seen situations where listening excessively to customers resulted in a great product or service the customer was delighted with but nearly bankrupt the organization. 

Coexistence is the best way to describe it.  At certain points in a process improvement project, you should pull out the lean tools.  Example are when you look at the existing processes or processes and propose new ones.  At other times in the same project don’t forget the six sigma tools such as the voice of the customer and critical to quality.  So like many areas of life the need is for balance.