Lean vs Six Sigma

Lean vs Six Sigma

→ Lean Manufacturing focuses on the removal of waste from the system and Six Sigma focuses on reducing the variation from the product or process.
→ The concept of Lean Manufacturing was firstly suggested by the Toyota Production System.
→ Motorola primarily introduced Six Sigma in the year 1986 which ensures that 3.4 ppm of defect of manufactured products.

Lean Process

→ It is an organized sequence of operations used for eliminating wastes.
→ The 8 wastes of Lean Manufacturing are Transportation, Inventory, Motion, Waiting, Over Production, Over Processing, Defect generation, Skill-set.
→ Toyota Production System introduced the concept of Lean Thinking  & operation in the 1990's.
→ The elimination of wastes can be done by analyzing every process and non-productive steps.
→ There are two main concepts are Just in Time (JIT) and Jidoka.



The Five Fundamental Principles:

  1. Identification of value
  2. Ascertainment of value stream
  3. Flow of Activities
  4. Pull
  5. Perfection

Six Sigma

→ Motorola introduced the Six Sigma Methodology in 1986.
→ This methodology is used for maintaining and improving the Quality of Products and processes also this methodology focuses on providing products and services with the highest quality.
→ After the success of Motorola, many other organizations have also implemented the 6𝛔.
→ The foundation of the 6𝛔 technique in probability and normal distribution.

Two methodologies for implementing six sigma:

[1] DMAIC (Define, Measure, Analyze, Improve, Control): When the improvements are made in the existing product, service or operation.
[2] DMADV (Define, Measure, Analyze, Design, Verify): When a new product, service or operation is designed.


Difference between Lean Manufacturing [LM] and Six Sigma [SS] Methodology

[1] Definition
→ Lean Manufacturing eliminate wastes from system or process
→ Six Sigma reduces the variation from the product or process

[2] Introduced
→ LM was initiated in the 1990's by the Toyota Production System (Toyota Motors)
→ SS was initiated in the 1980s by the Motorola

[3] Major focus
→ LM focuses on the process flow.
→ SS focuses on the problem.

[4] Tools used
Lean Manufacturing Tools are used for the improvement project like 5S methodology, Poka-Yoke, Kaizen, etc
→ SS: Statistical Tools are used for the improvement project like Control Chart, Histogram, Scatter Diagram, etc

[5] Nature of Control
→ LM focuses on visual control
→ SS focuses on statistical process control

[6] Methodology
→ LM: To eliminate eight wastes (i.e. TIMWOODS such as Transportation, Inventory, Motion, Waiting, Over Production, Over Processing, Defect generation, Skill-set)
→ SS: DMAIC Methodology (Define, Measure, Analyze, Improve, Control)  or other methodology for new product or process is DMADV (Define, Measure, Analyze, Design, Verify) methodologies are used.

[7] Major benefits
→ LM: Improve production by increasing productivity
→ SS: This methodology improves profit and quality of the product

👉 Also Read:
      1. 5S Methodology



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