(Lean) Six Sigma - Everything You Need to Know!

Lean Six Sigma is an integrated methodology that combines the principles of Lean Management with the goals of Six Sigma. The aim of this combination is optimal process improvement, allowing companies to achieve maximum results. Lean Management promotes flat hierarchies and short communication channels, while Six Sigma aims to make processes largely error-free.

Emergence of Lean Six Sigma

The emergence of Lean Six Sigma is closely tied to the history of Toyota. The pursuit of excellence and the elimination of waste have always been ingrained in the company’s DNA. Although the company is often associated with the Toyota Production System and the principle of Kaizen, Toyota’s commitment to quality extends beyond these fundamental elements. One of the methods Toyota has used to ensure unparalleled quality is the Six Sigma approach.

Six Sigma at Toyota

Toyota has integrated Six Sigma into its processes and successfully used it to elevate quality to an unmatched level. This methodology has helped increase production efficiency while ensuring quality. It relies on data-driven decisions and statistical analysis to minimize errors and optimize processes.

The Synergy of Lean Six Sigma

By combining Lean Management and Six Sigma, companies gain a powerful methodology for process optimization. Lean Management allows for maximizing efficiency and reducing waste, while Six Sigma ensures quality and minimizes errors. This synergy contributes to enhancing the overall performance of a company by focusing on both efficiency and quality.

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The Six Sigma Cycle - DMAIC

The Lean Six Sigma method is based on the DMAIC cycle, which divides the process of quality control into several phases:

  • Define Phase – In this phase, problems are identified and named. The business leader organizes planning and sets project goals.
  • Measure Phase – This phase involves measuring the variables necessary for the project. It addresses questions such as whether the measurement systems are ready and whether all necessary conditions have been met.
  • Analyze Phase – This phase is used by the leader to evaluate the measurement results. In the subsequent process, the root causes of the problems are identified.
  • Improve Phase – In this step, the focus is on developing solutions. Supportive measures such as brainstorming and brainwriting are employed. Once the solutions are known, they can be implemented.
  • Control Phase – The final phase includes a final check on the effectiveness of the actions taken. If there are deviations from the planned requirements, countermeasures must be developed.


Lean Six Sigma is an impressive methodology that helps companies optimize their processes while ensuring high quality. This combination contributes to reducing waste, shortening lead times, and increasing customer satisfaction. The integration of Lean Management and Six Sigma is a powerful tool that assists companies in being successful in a competitive world.

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