{"id":16377,"date":"2024-06-11T09:44:13","date_gmt":"2024-06-11T08:44:13","guid":{"rendered":"https:\/\/ezfactory.nl\/?p=16377"},"modified":"2026-04-13T10:40:28","modified_gmt":"2026-04-13T09:40:28","slug":"what-is-lean-six-sigma","status":"publish","type":"post","link":"https:\/\/ezfactory.nl\/en\/knowledge-base\/what-is-lean-six-sigma\/","title":{"rendered":"Lean Six Sigma as the key to smarter and safer production"},"content":{"rendered":"
[vc_row][vc_column][vc_column_text css=””]In today\u2019s manufacturing world, the pressure to produce more safely, sustainably, and efficiently is greater than ever. To meet these challenges, companies increasingly focus on process improvement – something for which the Lean Six Sigma method provides a strong foundation. In this blog, we explain how the Lean Six Sigma method works in practice and why it is so valuable. But let\u2019s start with the key question: What is Lean Six Sigma?<\/span><\/p>\n

What is Lean Six Sigma?<\/span><\/h2>\n

First of all, it is important to understand that the Lean Six Sigma method consists of two distinct methodologies: Lean and Six Sigma. Lean focuses on eliminating waste and creating flow, while Six Sigma focuses on reducing deviations from the standard and increasing quality. Lean is centred around speed, simplicity, and customer value, whereas Six Sigma provides depth, data-driven decision-making, and structured problem-solving. A great team, in other words! By applying Lean Six Sigma, you work with the best of both worlds: creating value for the customer, eliminating waste, reducing variation, and continuously improving based on facts and data.<\/span><\/p>\n

Why is Lean Six Sigma important for factories?<\/span><\/h2>\n

Factories deal daily with the complexity of machines, people, procedures, material flows, safety standards, and quality requirements. Everything must be aligned, and if even one link in the chain is not functioning optimally, problems arise immediately. Think of downtime, quality deviations, safety risks, and unnecessary costs. Lean Six Sigma offers factories a structured way to prevent or solve these issues. Applying Lean Six Sigma shows its value not only in KPI results but also in fostering a culture in which improvements become part of the daily work\u2014carried out safely and consistently.<\/span><\/p>\n

The 5 principles of Lean Six Sigma applied in practice<\/span><\/h2>\n

To truly understand Lean Six Sigma, it is important to clearly distinguish between the five core principles. These core principles, also known as Lean Six Sigma tools, are explained one by one below.<\/span><\/p>\n

Define value from the customer\u2019s perspective<\/span><\/h3>\n

The methodology begins with identifying what creates value for the customer. This might include products that are free of defects, delivered on time, consistently high in quality, and competitively priced. Once you map out what actually adds value for the customer, you can also determine which activities do not add value. These non\u2013value-adding activities then become the starting point for implementing improvements.<\/span><\/p>\n

Identify and eliminate waste<\/span><\/h3>\n

Lean distinguishes eight types of waste, including overproduction, waiting time, transport, defects, and unnecessary motion. These wastes are often easy to recognize on the shop floor. For example, an operator spends a long time searching for the right tool, a machine suddenly stops because materials are missing, or a production line produces more than requested. By making waste visible (with the help of digital workplace tools), teams can improve in a targeted way.<\/span><\/p>\n

Create a streamlined flow<\/span><\/h3>\n

A good flow means that products or processes move through the system smoothly, without interruptions. Evidence of good flow can be seen in short lead times, a well-organized line layout, and process steps that are well aligned. With a streamlined flow, you benefit from less waiting time, lower inventory, fewer opportunities for errors, and better predictability.<\/span><\/p>\n

Work with pull instead of push<\/span><\/h3>\n

In traditional manufacturing, production often follows the push principle, producing simply because it is scheduled. Lean, however, uses the pull principle, meaning production only happens when the customer requests it. This prevents overproduction and ensures that processes are better aligned with customer demand. Pull systems can be seen in digital dashboards that show operators what is needed and when, as well as in inventory signalling systems.<\/span><\/p>\n

Strive for perfection through continuous improvement<\/span><\/h3>\n

Lean is all about Kaizen: improving a little bit every day. Not large, one-off projects, but small, structured improvement steps that collectively make a big difference. Lean Six Sigma tools fit seamlessly with quality software and the process of continuous improvement. However, this requires a culture in which employees actively identify improvement opportunities and where data helps to make improvements long-lasting.<\/span><\/p>\n

The 6 core points of Six Sigma \u2014 Step by step<\/span><\/h2>\n

Six Sigma follows the DMAIC cycle. This contains five steps: Define, Measure, Analyse, Improve and Control and is therefore supplemented by a sixth step: Standardize. With this systematic approach you ensure that problems are solved properly and do not recur. Below we briefly describe how the six steps of Six Sigma work.<\/span><\/p>\n

Define the problem and the scope<\/span><\/h3>\n

In the first step the problem is described clearly. This step prevents teams from treating symptoms or from starting too broadly. Questions that can help here include:<\/span><\/p>\n