Summary and Introduction to Lean Six Sigma



A Lean Six Sigma transformation can enable operations to drive the overall business strategy, through the creation of many tangible business benefits. Quality may increase through improved process yields and reduce scrap and rectification costs. Cost improves through reduced conversion costs, improved cash flow, and higher return on assets. Delivery can improve through shortened production lead times which more flexible operations that can respond quickly to changes in customer demand.


Despite attempts, most businesses have not been able to capture or sustain the benefits of a Lean Six Sigma transformation. Lean Six Sigma represents a fundamental change and most businesses have pursued change in tactical, rather than a strategic manner. Most failed Lean Six Sigma transformations can be attributed to lack of true senior management commitment and understanding of the change process. Moreover, the methodology of many companies is to rely on a series of quick-hit approaches that deliver short term benefits, but aren’t sustainable in the longer term. Add to this the reluctance of many companies to consider the business as a whole rather than just concentrating on operations or manufacturing and you have a recipe for failure.


The team at Beyondlean have recognised and experienced these potential pitfalls and have created a programme that can help lead a business through the change process. The Beyondlean Lean Six Sigma roadmap takes a narrow and deep approach by focusing on a model value stream. The Beyondlean Roadmap creates the Lean Six Sigma infrastructure to maximise the chance of sustainability. Ultimately, the Beyondlean Roadmap cannot guarantee the sustainability of the system if the business is not willing to invest the required time, resource, and commitment to the change process. If a business is ready to embark on this Lean Six Sigma journey, then manufacturing operations can not only become a competitive advantage, but also deliver new strategic opportunities.


An Introduction to Lean Six Sigma


The purpose of the Beyond Lean Roadmap is to guide clients through the Lean Six Sigma transformation process. Many organisations have attempted Lean Six Sigma transformations, and most have failed through several key pitfalls. The team at Beyond Lean has recognised these pitfalls and developed this programme to ensure maximum chance of sustainability for such a transformation. The basis of this programme is a structured and methodical approach to change while encouraging maximum knowledge transfer of Lean Six Sigma concepts to the Business through the application of the accompanying material. It takes significant effort to first maintain and then improve a system. The client must be willing to commit the required time, resource, and attention to ultimately succeed in a Lean Six Sigma transformation.

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