Time and again since 20 years Lean and Six Sigma methodologies have proved dramatic improvements in productivity and cost savings by focussing on process performance.

While Six Sigma dwells into reducing variation and improving process yields by following a problem solving approach using statistical tools, lean primarily is concerned with eliminating wastes and improving flow by following Lean principles.

Best quote of companies using these methodologies are GE, Motorola and Toyota have proven world that these methodologies can bring in the best from their employees.

However using either one of them might have limitations. Six Sigma will eliminate defects but will never address the process flow optimization. At the same time Lean principle excludes statistical analysis. Therefore practitioners only believe to integrate the two beautiful concepts of lean and Six Sigma is the road ahead.

Example: Inventory reduction not only requires reducing batch sizes and linking operations by using lean, but also minimizing process variation by utilizing Six Sigma tools.

The Integrated approach would include :

1. Using Value Stream Mapping to develop a pipeline of projects that lend them either to apply lean or Six Sigma Tools
2. Teaching lean principles first to increase momentum and then using Six Sigma to tackle complex solutions. Simple rules definitely will apply towards Define,Measure,Ananlyse,Improve and Control.