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Lean and sixsigma are certificates sold by companys for profit. Normaly these companies will advise the buyer on how to run there business and will acredit them when they can show that they have paperwork to match their criteria. Lean critera would involve minimising the stock held "in house" as in "Just in Time" managment founded by the Ford motor company in the 1920's and minimising footfall in doing certain procedures as in time managment. Sixsigma would involve minimising product defect to within defined criteria as in Total Quality Managment(TQM) refer to Dr E W Deming circa 1950 and Philip Crosby (Zero defects) circa 1960. Niether of these ideas are new in business management And the quality of the awards/criteria for being awarded can vary between companies.

Answer

LEAN is a set of principles, concepts and techniques designed for the relentness elimination of waste .for producing a "JUST IN TIME "system that would deliver to our customers, aim to keep zero stock.

*what they exactly want

*when they need it

*In the quality they need

*In the right sequence

*In the lowest possible cost

SIX SIGMA is reducing variation and eliminating defects, target to achieve zero defect..

Six sigma quality process (1.5 sigma shifted) giving a result 3.4 defects per million opportunities.

ONCE WASTE IS ELIMINATED BY USING LEAN,ONE CAN APPLY SIX SIGMA TO REDUCE VARIABILITYAND SUSTAIN THE PRODUCTION TO BE NEAR PERFECT.

Lean is a tool used in the manufacturing or processing industry that helps eliminate waste. Waste is define as anything that does not add any value to the process, also known as Muda.

Six Sigma is a quality control tool that reduces variability in production. Six sigma doesn't allow more than 3.4 defects per million of opportunity. Opportunity is defined as what the customer wants, their expectations.

Once waste is eliminated by using lean, one can apply six sigma to reduce variability and sustain the production to be near perfect.

The goal of Six Sigma is to increase profits by eliminating variability, defects and waste that undermine customer loyalty.

Six Sigma can be understood/perceived at three levels:

  1. Metric: 3.4 Defects Per Million Opportunities. DPMO allows you to take complexity of product/process into account. Rule of thumb is to consider at least three opportunities for a physical part/component - one for form, one for fit and one for function, in absence of better considerations. Also you want to be Six Sigma in the Critical to Quality characteristics and not the whole unit/characteristics.
  2. Methodology: DMAIC/DFSS structured problem solving roadmap and tools.
  3. Philosophy: Reduce variation in your business and take customer-focused, data driven decisions.

Six Sigma is a methodology that provides businesses with the tools to improve the capability of their business processes. This increase in performance and decrease in process variation leads to defect reduction and vast improvement in profits, employee morale and quality of product.

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Six Sigma is a rigorous and a systematic methodology that utilizes information (management by facts) and statistical analysis to measure and improve a company's operational performance, practices and systems by identifying and preventing 'defects' in manufacturing and service-related processes in order to anticipate and exceed expectations of all stakeholders to accomplish effectiveness.

I use a software system that will talk to you with audio as it walks you through the entire methodology. I like to refer to it as my professor in a computer. It has all the templates and tools for statistical analysis, reads and reports the analysis and archives the report while providing a complete tracking system, provide training and best for a large team driving multiple projects. Too much more to say.

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Someone above me mentioned Muda--waste. According to Ohno, there are seven kinds of waste: overproduction, unnecessary transportation, inventory, motion, defects, overprocessing and waiting. Other sources identify latent skill, danger, poor information, material and breakdown as sources of Muda. Ohno also claims Mura--unevenness--and Muri--unreasonableness--as wastes.

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