Shop-floor profit leaks hide in wait states, defects, and rework. Lean hunts for the waits; Six Sigma hunts for the variation.

  • Waste purge: A biopharma line found 54 % of its production cycle was pure waste and mapped fixes to remove it. SpringerLink
  • Scrap plummet: A medical-device plant drove scrap from 70 000 ppm to 10 000 ppm (-86 %) and saved US $174 k in material plus US $205 k labor. Juran Institute
  • First-pass yield jump: Sheet-metal parts right-first-time rose from 60 % to 87 % in two months; DPMO crashed 87 968 ➜ 15 015. GoLeanSixSigma.com (GLSS)
  1. Value-stream map line-to-line — expose idle queues and double handling.
  2. 5S workstations — labeled tools, clear floors, instant audits.
  3. Kanban WIP limits — visual caps keep flow steady.
  4. Obeya board — daily display of takt, defects, downtime.
Metric Track Why It Helps
First-pass yield (FPY) Good units ÷ total units Shows hidden rework cost
Scrap rate (ppm) Defective parts per million Direct material loss
Cycle time Minutes from start to pack Reveals bottlenecks
OEE Availability × Performance × Quality One view of true capacity

DMAIC takes each metric from baseline → root cause → pilot → control.

  • Removing two non-value steps cut 54 % of total cycle.
  • Standardized glue tips, 5S, and split stations slashed scrap to 10 000 ppm and freed US $413 k.
  • 5S + Kanban boosted first-pass yield 27 points and trimmed order lead time by 10 days.
  1. Pick one pain — FPY or scrap is visible and countable.
  2. Map the flow — every touch, wait, and walk.
  3. Tag each step — value-add, required, waste; delete pure waste.
  4. Baseline numbers — ppm, minutes, $.
  5. Analyze causes — 5 Whys, Pareto, regression.
  6. Pilot fixes — one cell or shift.
  7. Control — SOPs, dashboards, weekly audits.

Lean Six Sigma in Production / Operations means fewer defects, faster cycles, and money back to the bottom line. Start with one metric, remove waste, reduce variation, lock the gain, repeat.

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