Programme design and deployment plan
We define the Champion, Black Belt and Green Belt roles, project selection criteria and the way results are tracked, to fit your organisation.
Solutions · 02
Lean Six Sigma Consulting
Lean Six Sigma combines Lean's focus on flow and waste with the statistical discipline of Six Sigma. We do not bring it to your organisation as a training calendar, but as a programme of well-chosen projects, developing belt holders and tracked financial results.
- 1,000+
- improvement projects
- 500+
- certified participants
- MBB
- led by a Master Black Belt
What is Lean Six Sigma?
Chronic quality problems are often tackled by guesswork: a setting is changed, an inspection is added, the problem disappears for a while and then comes back. This is where Six Sigma comes in. It measures the problem first, proves the source of variation statistically, and only then designs a solution.
Lean brings speed and flow. Used together, they cut the defect rate and make the process run with less inventory and shorter lead times. Our job is to establish both disciplines in your organisation as a programme your own people can run.
Scope
What the work covers
Project selection and scoping
A poorly chosen project wears out even the best-trained team. We derive projects from loss data and customer complaints and pin them down with a project charter.
Belt programmes
White, Yellow, Green and Black Belt training runs alongside real projects, so a tool learned this week is used on the shop floor the same week.
Project coaching and tollgate reviews
At the end of each DMAIC phase we review the data with the team and decide together whether the project is ready to move on.
Advanced statistical tools
We reduce variation at its source with Design of Experiments (DoE), Measurement System Analysis (MSA), Statistical Process Control (SPC), regression and hypothesis testing.
Financial validation
Project savings are calculated with a method agreed in advance with your finance team, so the reported figure is one the accounts will recognise.
How we work
DMAIC: the five steps of a project
- 1
Define
We set out the problem, its customer impact, the target and the project boundaries in a project charter.
- 2
Measure
We test whether the measurement system can be trusted using MSA and establish current performance with data.
- 3
Analyze
We list the possible causes and use statistical tests to prove which ones actually matter.
- 4
Improve
We trial and verify solutions to the root causes at pilot scale, using Design of Experiments where needed.
- 5
Control
A control plan, SPC and standard work make sure the problem does not return.
What changes?
- Chronic quality problems are closed with a proven root cause, not a guess.
- You trust your measurement system, and decisions rest on solid data.
- Thanks to control plans and SPC, solved problems stay solved.
- You have Green and Black Belts in-house who can run projects on their own.
Who is it for?
- Manufacturers dealing with recurring quality problems, high scrap or customer complaints
- Industries where process variation directly affects product quality
- Quality and continuous improvement teams that want to build in-house problem-solving capability
- Organisations whose belt holders are trained but struggle to bring projects to a result
Frequently asked questions
Common questions.
What is Lean Six Sigma?
Lean Six Sigma is an improvement approach that combines Lean, which removes waste and speeds up flow, with Six Sigma, which reduces process variation using statistical methods. Projects usually follow the DMAIC steps: Define, Measure, Analyze, Improve and Control.
What does “sigma” mean in Six Sigma?
Sigma (σ) is the statistical term for standard deviation, the measure of variation in a process. A process running at Six Sigma level is expected to produce about 3.4 defects per million opportunities. The aim is to reduce variation until the process sits well inside the customer's limits.
What is DMAIC?
DMAIC stands for Define, Measure, Analyze, Improve and Control. It is the core Six Sigma project roadmap for solving a problem in an existing process on the basis of data.
How long does a Lean Six Sigma project take?
It depends on the scope of the problem and how readily the data is available. In general, Green Belt projects are completed within a few months, while wider Black Belt projects take somewhat longer. Target dates are set at the start in the project charter.
What is the difference between training and consulting?
Training gives belt holders the methods and tools. Consulting covers programme design, project selection, coaching and validation of results. In most organisations the two run together, so tools learned in training are applied to real projects with coaching.
Led by
Abbas Erdenal
Lean Six Sigma Master Black Belt · Founder of Fega Partner
More than 25 years on the shop floor, over 1,000 improvement projects and programmes delivered in seven countries. Abbas Erdenal personally leads every consulting engagement and training.
About Abbas Erdenal