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Lean Six Sigma A to Z Guide for Dummies
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Table of Contents
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Introduction
Lean Six Sigma (LSS) is an approach to management
that focuses on streamlining business processes
and boosting customer satisfaction, to deliver
customer value. This approach is supported by a
set of tools, methodologies and frameworks that
deliver this value. Efficient operational
processes and quality outcomes are a result of
minimizing variances and removing discrepancies.
The benefit of using Six Sigma is to help
companies produce better products and services.
LSS as a part of the organizations strategy
enables meeting the needs of customers, clients,
or end-users. This guide is written for readers
who would want a basic understanding of the
concept of Six Sigma. Then on, they can take up
the Six Sigma Combo course to upskill and expand
their skill-set as a Lean Six Sigma manager.
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History of Six Sigma,
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Lean, and Their Differences
Six Sigma history dates back to the 19th-century
mathematician Carl Friedrich Gauss who
introduced the idea of a normal curve. In the
1920s Six Sigma was used as a measurement
standard in product variation, American engineer
Walter Shewhart contributed to the advancement
of Six Sigma and process improvement. In 1985, an
engineer named Bill Smith coined the name Six
Sigma. Motorola engineers and Chairman Bob
Galvin adopted Six Sigma as a quality management
technique for detecting defects and optimizing
business processes. In fact, the process was so
effective that Motorola saved more than USD 16
billion from adopting this approach. Since then,
countless companies spanning multiple industries
have implemented Six Sigma.
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Lean Six Sigma can be traced back to 2000 when it
first forked out of Six Sigma and became an
individual process. The concept was designed as a
part of Toyota Production Systems and embraced
ideas from lean manufacturing.
There has been a constant debate in the
business world about
Lean Improve process through the reduction or
elimination or elimate of wastage. Focus Lean
focuses on waste elimination and support six
sigma quality process.
Six Sigma
Improve process through the reduction or
variation. Focus Six sigma focuses on reducing
the variation in quality and supports lean
speed.
which methodology is more effective whether
Lean or Six Sigma for
minimizing costs and reducing wastage. However,
both of these concepts have similar objectives
but undertake different approaches to determine
the root cause of waste. On one hand, Six Sigma
is a group of effective techniques leveraged to
minimize the rate of errors. On the other, Lean
is a systematic way of removing waste and
designing a seamless flow in the production
process.
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What is Lean Six Sigma
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Lean and Six Sigma are the two crucial process
improvement methods that together make Lean Six
Sigma for achieving operational excellence. It is
well- recognized as a data-driven and fact-based
improvement philosophy that gives importance to
detect prevention more than detect
detection. The Lean principle focuses on
reducing or removing process waste. Six Sigma
helps in variation-reduction in processes.
Combined, Lean Six Sigma improves the efficiency
and quality of the process across industries,
ranging from manufacturing, electronics, online
retailing to healthcare. The fundamental idea
behind Lean Six Sigma is to provide the
organizations with a path to realize their
missions quickly and efficiently. Lean Six Sigma
depends on a collaborative team effort to
optimize performance by eliminating waste and
minimizing variation for achieving bottom-line
results and customer satisfaction.
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Fundamental Principles of Lean Six Sigma
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• Three crucial elements add up as the basics of
  Lean Six Sigma. They include
• Tools Techniques - A designed set of tools and
  methodologies to identify and fix problems.
• The Modus Operandi - A sequence of phases that
  put the problem-solving techniques for precisely
  implementing the solution by determining the root
  cause of the problem.
• Psyche Culture - A mannerism that depends on
  data and processes to keep improving and realize
  operational performance objectives.

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What is DMAIC
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ANALYZE Analyze Data Identify Root
cause Identify and Remove wastes
IMPROVE Generate Solutions Evaluate
Solutions Optimize Solutions Pilot Plan
and implement
DEFINE Launch Team Estalish Charter Plan
Project Gather the
MEASURE Document the Process Collect baseline
data Narrow Proj- ect focus
CONTROL Control the Process Validate project
benefits
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Crucial Lean Six Sigma Tools
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DMAIC stands for Define, Measure, Analyze,
Improve, and Control which is a highly effective
five-phase method and problem-solving approach
that drives the Lean Six Sigma. DMAIC involves a
data-driven improvement cycle used for
improving, optimizing, stabilizing business
processes.
II. Critical to Quality (CTQ) Critical to Quality
(CTQ) is a crucial tool used while designing new
products or services for a business. CTQs are
measurable data needed on a specific product or
service that your customers have specified as
extremely important.
III. Value Stream Maps Value Stream Maps are lean
tools that use flow chart documenting at every
phase in the project. According to lean experts,
this methodology is fundamental
Besides, DMAIC isnt restricted to Six Sigma and
can be deployed in other improvement
applications as well. The key objective of DMAIC
is to remove costly variations from
manufacturing and business processes.
for minimizing process cycle times,
identifying waste, and implementing process
improvement seamlessly.
I. SIPOC Diagrams SIPOC Diagrams are the tools
that help in defining complex projects that
arent
IV. Voice of the Customer A specific statement
made by customers on specific products or
services is called the Voice of the Customer.
This includes user expectations, comments and
preferences.
scoped properly. Teams use these diagrams before
the project work begins to determine all the
relevant methods.
SIPOC Diagram
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DiagramValue Stream Map
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V. Voice of the Process It guides you on what
needs to be improved by providing all the
information from the current processes. This
includes various data for your organization such
as maintenance, shortcomings and downtime.
IX. Sampling Sampling is the process of picking a
small number of elements from a larger defined
target group. The two techniques for
accomplishing this are probability sampling or
non-probability sampling.
X. Process Control Process control is a control
technique for confirming that the process
performance is sustained at the level. It
facilitates ongoing improvement and fulfills
customers requirements.
VI. Cost of Poor Quality Cost of Poor Quality
(COPQ) are costs engendered because of
manufacturing faulty material. Also included are
the costs involved in bridging the gap between
the real and desired product.
Poka-Yoke is a fundamental tool for making a
process mistake-proof by targeting mistakes and
defects. This helps in removing inaccuracy by
developing systems that instantly either prevent
or identify the mistakes.
VII. Process Mean Variation It is a theory of
significance that happens when processes fail to
stick to a definite pattern and is the primary
cause of quality issues cropping up in
production or transactional processes.
XII. Continuous Improvement Six Sigma is a
widely-accepted lean version that is a data-drive
n and
VIII. Multi-vari Chart
Multi-vari chart analysis help in determining
the sources of variation. They are used to
observe time to time,
sophisticated approach to Continuous
Improvement. It is an intentional and dynamic
practice focused on removing variances and
boosting predictability in businesses.
piece to piece and within piece variations.
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XIII. Hypothesis Testing
Hypothesis in identifying
testing helps whether the in
observed variations
between two or more samples is because of random
chance or due to actual differences by
leveraging statistical analysis. XIV. Regression
Correlation Regression and correlation test the
relationships and not the means or variations.
These tools help teams in controlling the key
inputs by finding out the variables and the
degree they affect the response.
XV. Design of Experiments This lean tool helps
project teams to figure out the impact of
various inputs of the processes on the end
product. Companies hire Lean Six Sigma certified
professionals so they dont have to invest
additional funds in designing Lean Six Sigma
Strategies. Certified employees can train other
team members and educate them about relevant
principles.
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Lean Six Sigma Certifications
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the different Six Sigma tools and techniques.
Lean Six Sigma certifications are classified
into four levels or categories referred to as
belts that are awarded to the learners in a
hierarchical format. Lets take a look at the
four levels of Lean Six Sigma certification
courses
II. Green Belt Certificate Lean Six Sigma Green
Belt certificate is an advanced level that
involves a thorough understanding of all the
aspects of
the program. Course undertakers get a complete
idea of implementing, performing, interpreting,
and applying the principles of Lean Six Sigma at
a high level of proficiency.
I. Yellow Belt Certificate Lean Six Sigma
Yellow Belt certificate comprises the
fundamental aspects of the method that helps the
learners understand how to implement, perform,
interpret, and apply the concepts in a skilled
yet limited context. It is best suited for
beginners who want to acquire knowledge about
It is ideal for professionals who are either
serving as team members in more complex
improvement projects or
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III. Black Belt Certificate Lean Six Sigma
Black Belt certificate provides a comprehensive
understanding of the advanced Six Sigma
methodologies and techniques. Professionals who
have this certificate qualify for managerial
positions. This certificate is best suited for
IV. Master Black Belt Master Black Belt is the
highest level in Lean Six Sigma certification
levels. It can be taken up by the individuals
whove earned the Black Belt certification. The
holders of this certification are referred to as
champions who act as mentors to the Black Belt
Lean Six Sigma professionals. A Lean Six Sigma
certification is crucial from a professionals
perspective as it gives them an edge over others
as these certifications are highly recognized by
organizations worldwide.
individuals who work in a full-time capacity and
lead complex improvement projects. Also, the
individuals whove earned the Lean Six Sigma
Green Belt certificate are eligible for
enrolling in the Black Belt certificate.
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The Lean Six Sigma Glossary
1. Accuracy It is the difference between the true
value and the set of numbers by having data or
results centered on a familiar target.
Alternative hypothesis is crucial for making the
process of writing statements more intuitive.
4. Balanced Scorecard A management methodology to
align the Key Business Objectives (KBO) of an
organization with enterprise activities, a
balanced scorecard helps in keeping everything
in check. Measuring performance in various areas
like finance, customer satisfaction and
innovation is a crucial aspect of a balanced
scorecard.
2. Affinity Diagram The affinity diagram is used
to facilitate a brainstorming session to get
lots of ideas quickly by displaying activities
in affinity or homogeneous groupings.
3. Alternative Hypothesis The alternative
hypothesis is the opposite of the null
hypothesis and cannot be anticipated through
randomness.
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5. Benchmarking Benchmarking is used by
organizations to compare the performance of
their outputs with that of industry standards.
fish, a cause-effect diagram is a graphical tool
for showcasing various causes associated with a
particular effect.
8. Charter It is a project document comprising
the fundamentals such as business case, problem
statement, and scope along with their
descriptions.
6. Capability Ratio The opposite of the Cp index,
capability ration involves dividing the process
spread with the specification spread for
understanding the percentage of specification
window consuming by process variation.
9. Chi-square Distribution This is a statistical
tool to compare a target variance against an
observed variance for checking goodness-of-fit
or dependence or independence ratio.
7. Cause-effect Diagram Also called the fishbone
diagram because of its resemblance to the
skeleton of a
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13. Effort/Impact Matrix Impact/effort matrix is
the other name for the Effort/Impact matrix that
guides the team to identify which among the
various solutions that look the easiest can be
implemented and have a beneficial influence.
10. Data Collection Plan Data Collection Plan is
a tactical plan comprising nine columns for
collecting both baseline data and the data that
can offer hints to the root cause.
11. Descriptive Statistics Mean and median are
the measures of central tendency, standard
deviation and range of dispersion are used to
summarize and interpret properties of the data
set referred to as descriptive statistics.
14. Factorial Experiment A factorial experiment
can be of two types either full factorial'' or
fractional
factorial which is a concurrent manipulation of
factors at different stages to analyze their
impact on a specific desired outcome.
12. Design for Six Sigma Design for Six Sigma
(DFSS) uses a DMADV approach which signifies -
Define, Measure, Analyze, Design, and Verify.
Progressive organizations leverage the Six Sigma
philosophy to build into the design processes.
15. Flowchart It's a graphical tool to represent
distinct steps of the process in a systematic
order. Starting from the top and moving to the
bottom of a page to interpret performance
information and include all the critical steps
to the process.
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16. Force Field Analysis It is an analysis tool
used for visualizing the restraining forces and
driving forces that have an impact on some
specific area of interest.
21. Inferential Statistics Inferential statistics
are used to make
generalizations, approximations, or projections.
It is the sample thats taken from inference
space, a mathematical method for inferring the
properties of a population with the help of
probability theory.
17. Gemba Gemba in Japanese means the place. It
is the place where value is added and all
activities usually take place.
22. Inference Space Inference Space is a
mathematical technique for deducing the
properties of a population by using probability
theory from which the sample thats taken is
known as inferential statistics.
18. Goldratts Theory of Constraints Theory of
Constraints is inspired by the book The Goal
by Eliyahu M. Goldratt. This theory resembles
the notion of the adage, a chain is only as
strong as its weakest link and believes that in
a series of steps the slowest step controls the
entire flow.
23. Interrelationship Diagrams (also known as
digraphs) It graphically displays the
cause-effect relationships existing among a
group of issues, problems, opportunities, or
items. Interrelationship Diagrams are used to
identify the potential causal
19. Hypothesis (alternate/alternative) There are
two hypotheses alternative and null where the
first one is the opposite of the latter. The
null hypothesis is what
relationships hidden behind issues that are
occurring continuously despite taking preventive
measures to solve them.
you forecast through randomness but the
alternate hypothesis cant be anticipated like
that.
20. Hypothesis Testing It is a method to make
logical decisions about the actuality of
effects. The decisions are incomplete and are
made by choosing from one or more options.
24. Ishikawa Tools (also known as Seven Basic
Tools) These tools comprise Cause-Effect
Diagram, Check Sheet, Control Chart, Histogram,
Pareto Chart, Scatter Diagram, and Run Chart.
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means through which JIT is achieved. Kanban is a
scheduling system for Just- In-Time (JIT) and
lean production.
25. Jidoka It is one of the guiding principles of
the Toyota Production System used to identify
unusual working conditions and instantly pausing
the work to remove the root cause of the problem.
29. Kano Model Kano Model categorizes the
qualities of products and services based on
the customers voice. Basic needs, performance,
and excitement are three classifications for
making better design decisions.
26. Kaizen Kaizen a Japanese word that means
improvement which has evolved since the 1950s
to a popular business strategy focused on making
small but constant changes in company operations
for betterment.
30. Least Squares Method (Least Squares
Criterion) This is a statistical technique team
uses the linear equation with the least-squares
method that depicts the points found on the
scatter diagram for identifying the best fit for
a set of data points.
27. Kaizen Event Also known as kaizen blitz, this
event is a focused improvement project that can
realize sudden improvements in a short span of
which five days is the most common timeline.
31. Load Leveling (also known as production
leveling or production smoothing) Called
heijunka in the words of the lean guru Taiichi
Ohno, load levelling is a methodology to
minimize the mode of
28. Kanban Kanban is a Japanese term that means
signboard. According to Taiichi Ohno, Kanbans
creator, it is a
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Kaizen Event- Roadmap
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01 02
Conceptial Training
Kaizen on Factory Floor Area
Measure Improvement
Evalute Improvements
Present Celebrate
Create and map new process Apply rapid
implemetation
Discover Problem Measure Analyse Current
work process Brainstorm solutions formulate
Process improvements
Business Process Standard Operations 5S Kaizen
Methology Tools techniques
Establish New Standard Process Operate using
new standard process Finalise New standard
process Monitor control
Present Celebrate Present Results and
celebrate
waste and large fluctuations in the demands of
customers.
34. Measles Charts Also referred to as a defect
map, a measles chart is a defect location check
sheet prepared by gathering and examining the
data that envisions the item being evaluated.
32. Loss Function Designed by a Japanese quality
consultant and engineer Dr. Genichi Taguchi, the
loss function is a graph that demonstrates the
cost when your product varies from the value.
36. New Quality Management Tools
These are also called seven management and
planning (MP) tools developed by the Union of
Japanese Scientists and Engineers (JUSE) in
33. Matrix Diagram A matrix diagram is a tool
that picturizes the crucial relationship between
or among two or more groups. A matrix diagram
can be magnified to show strengths or various
aspects of the relationships.
1976 to promote communication information,
innovation, and efficiency in planning crucial
projects.
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41. Pareto Chart This is a bar graph named after
Vilfredo Paret, an Italian economist, and is
used to visualize the vital items vs. the
trivial items.
37. Nominal Scale This is a scale that lists
categories or names. There is no particular
order in nominal scale and the nominal data is
discrete.
42. Quality Control The concept of controlling
the activities and the operational methodologies
used to fulfill the requirements of quality is
called quality control.
38. Nominal Group Technique A decision-making
methodology used by teams to differentiate the
vital items from the insignificant ones.
43. Radar Chart Radar chart a graph in which each
data series has its specific axis and radiates
out from the focal point. It is used when
various characteristics need to be compromised
to a sweet spot that is most pleasing to
customers in a particular niche.
39. Ordinal Ordinal is the data arranged in
order. An ordinal scale can be used by
leveraging symbols or numbers to rank order
based on severity, strengths, or importance.
40. P Chart This chart can be used when the data
is in whole numbers. For example in counting
thats known as an attribute or discrete data.
It uses a varying sample size for detecting the
defectives in a sample size.
44. Scope Scope outlines the boundaries of the
project for keeping the team aligned, motivated,
focused, contained, and on purpose.
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41. Pareto Chart This is a bar graph named after
Vilfredo Paret, an Italian economist, and is
used to visualize the vital items vs. the
trivial items.
47. Value Stream Mapping A value stream map is a
tool to analyze the process for the existence of
excessive and superfluous activities for
providing the visibility of information and
material flow in a process.
42. Quality Control The concept of controlling
the activities and the operational methodologies
used to fulfill the requirements of quality is
called quality control.
48. Weibull Distribution One of the most common
methodologies
in reliability engineering, Weibull distribution
is used for the Weibull examination of failure
data by modeling several failure patterns along
with their relative ease of use.
43. Radar Chart Radar chart a graph in which each
data series has its specific axis and radiates
out from the focal point. It is used when
various characteristics need to be compromised
to a sweet spot that is most pleasing to
customers in a particular niche.
49. X-bar R Chart The role of an X-bar R chart is
to facilitate the team to monitor, control and
envision the behavior of variation in a process.
50. Z-Score Table The standard normal
distribution is another name for the Z-Score
table. It is used for large sample sizes
especially where the population is beyond n30
for various hypothesis tests such as tests on
proportions, single mean tests, and the
difference between two means.
44. Scope Scope outlines the boundaries of the
project for keeping the team aligned, motivated,
focused, contained, and on purpose.
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Lean Six Sigma FAQs Answered

• Who invented Six Sigma?
• In 1985 an engineer named Bill Smith invented
  Six Sigma.
• Who needs Six Sigma certification? Six Sigma
  certifications are best suited
  for individuals who are planning a career in
  Quality Management in any sector like
  healthcare, manufacturing, pharmaceutical,
  service industries, or technology.
• What is the use of Six Sigma Certification?
• Six Sigma provides individuals the knowledge of
  a designed set of tools and techniques for
  optimizing the business processes with an
  organization to get hired by companies in better
  roles.

• Which is the most recognized Six Sigma
  certification?
• ASQ or IASSC are the leaders in Six Sigma
  certifications. They are widely-recognized
  certifications world-wide.
• Is Lean Six Sigma Certification worth it?
• Yes, Lean Six Sigma certifications are
  beneficial because you implement your learning
  to solve real problems in an organization rather
  than just earning them for the sake of it.
• How long does it take to get certified as a lean
  six sigma green belt?
• Two to seven weeks is the average time to
  complete the lean six sigma green belt
  certification program.

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16. What is a good sigma level? Ideally, a
process with Sigma level 6 or more than 6 is
believed to be an excellent process.
12. Why is it called Six Sigma? Sigma signifies
the calculation of deviation in a data set.
Six is used because six standard deviation
events are needed before the process results in
an error.
17. Can I do Six Sigma Online? Yes, Six Sigma
training and exams are conducted online so you
can do it according to your convenience.
13. What is Six Sigma certified? Six Sigma
certification is the validation of a
professionals mastery of a well- recognized
technique of professional skills development.
18. What are the 5 principles of lean? The five
crucial lean principles are value, value stream,
flow, pull, and perfection.
14. What are the levels of Six Sigma?
There are five levels of Six Sigma
certifications White Belt, Yellow Belt, Green
Belt, Black Belt, and Master Black Belt.
19. Why is learning Lean Six Sigma
important? Lean Six Sigma certifications boost
your capabilities as a leader. Although job
duties vary industry-wise, most Six Sigma jobs
focus on improving processes, managing projects
and teams and analyzing data.
15. What are 6 Sigma tools? Six Sigma tools are
the problem-solving tools to facilitate Six
Sigma and other process improvement initiatives.
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Conclusion
Earning Lean Six Sigma credentials help
professionals in staying employable and
competitive in todays dynamic era. Employers
prefer hiring professionals with Lean Six Sigma
certification holders to ensure that their
production lines are led by quality and
process-driven individuals.
GreyCampus offers a comprehensive Lean Six Sigma
Certification course. Designed for working
professionals, this combo-course of Green and
Black Belt certification makes you proficient
in the implementation of methods and principles
of Lean Six Sigma. The online course is for
working professionals and job seekers. The goal
is to prepare them to satisfy the immense demand
for talent with lean expertise, skills and
certification.
The job options for professionals with Lean Six
Sigma certification are

• Six Sigma consultant
• Process engineer
• Manufacturing engineer
• Quality engineer
• Continuous improvement
• Operational excellence
• Project manager
• Mechanical engineer
• Industrial engineer
• Reliability engineer

20. Is there a difference between Six Sigma and
Lean Six Sigma? The primary difference between
Lean and Six Sigma is that Lean focuses on
eliminating waste and streamlining business
processes. On the other hand, Six Sigma strives
to minimize the rate of defects through a set of
techniques.
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