Process Optimization
Eliminate waste and improve efficiency with Lean Six Sigma
Proven methodology to reduce waste and eliminate variability. Results: 30-50% cost reduction, 40%+ productivity improvement. Black Belt certified team with experience in multiple industries.
DMAIC Methodology
The proven improvement cycle
Define problem, objective, scope, and project team
Measure current state, collect data, quantify waste
Identify root causes, validate with data
Design solutions, pilot, implement
Establish controls, SOPs, audits, ensure sustainability
Lean + Six Sigma = Efficiency + Quality
LEAN
Eliminate waste (activities that add no value). Origin: Toyota. Goal: do more with less, eliminate everything the customer doesn't value.
SIX SIGMA
Reduce variability and defects. Origin: Motorola. Goal: predictable processes with minimal variation, consistent quality.
LEAN + SIX SIGMA
Maximum efficiency (Lean) + Maximum quality (Six Sigma). Fast, efficient, and reliable operation.
When to use it?
The 8 hidden wastes destroying profitability
They typically represent 20-40% of your operational cost. They're in every company but most don't see them until someone external points them out.
TRANSPORT
Moving materials/information more than necessary
INVENTORY
More inventory than minimum necessary
MOTION
Physical movement that adds no value
WAITING
Dead time waiting for approvals/materials
OVERPROCESSING
Doing more than the customer requires
OVERPRODUCTION
Producing more than demanded
DEFECTS
Errors, rework, corrections
UNDERUTILIZED TALENT
Not leveraging team ideas and skills
DMAIC Methodology: the proven improvement cycle
DEFINE
1-2 weeks
Define problem, objective, scope, and project team
MEASURE
2-3 weeks
Measure current state, collect data, quantify waste
ANALYZE
2-3 weeks
Identify root causes, validate with data
IMPROVE
3-4 weeks
Design solutions, pilot, implement
CONTROL
Ongoing
Establish controls, SOPs, audits, ensure sustainability
What's included
Diagnosis
- Identification of processes with greatest opportunity
- Waste quantification
- Prioritization by impact vs effort
- Business case with projected ROI
DMAIC Execution
- Project structured in 5 phases
- Mixed team (consultants + your staff)
- Rigorous statistical analysis
- Real implementation
Lean Tools
- Value Stream Mapping
- 5S (organization)
- Kanban (visual control)
- Poka-Yoke (error-proofing)
Training
- Yellow Belt (fundamentals)
- Green Belt (project leaders)
- Coaching during projects
- Training materials
Typical results
Reduction in operational waste
Improvement in productivity
Reduction in cycle times
Reduction in inventory
Reduction in defects
Annual Kaizen initiatives executed internally
Who is Lean Six Sigma for?
Manufacturing & Production
Production lines, assembly, packaging. Typical 40-60% waste reduction.
Banking Operations
Credit processing, back-office. 30-50% reduction in cycle times.
Contact Centers
Customer service, technical support. +40% productivity per agent.
Logistics & Distribution
Warehouses, distribution centers. -30% picking time, -40% inventory.
Frequently Asked Questions about Lean Six Sigma
It depends on: identified waste, process complexity, available data, team certification scope. Free Lean diagnosis identifies opportunities and develops proposal with projected ROI.
Lean eliminates waste (activities without value). Six Sigma reduces variability and defects. Lean makes you fast. Six Sigma makes you consistent. Lean Six Sigma combines both: efficiency + quality.
No. Although it was born in manufacturing, today it applies to any repetitive process: banking, call centers, healthcare, government, professional services. If there's a repetitive process with waste, Lean can optimize it.
Lean Six Sigma certification levels. Yellow Belt: fundamentals. Green Belt: project leader. Black Belt: expert. Master Black Belt: mentor. We train and certify key personnel during projects.
Lean is NOT about firing; it's about doing more with what you have. We involve operators from day 1 in identifying waste because they know it best. Resistance drops when they see that Lean eliminates their daily frustrations.
Control phase ensures sustainability: SOPs, visual controls, audits, trained internal Green Belts. 80-85% of improvements are maintained at 2 years.
Ready to eliminate waste?
30-minute Lean diagnosis. We identify the 3 most costly wastes and estimate potential savings.