Lean vs. Six Sigma: What’s the Difference?
Two methodologies that have gained significant traction in achieving goals of efficiency and quality are Lean and Six Sigma. While often used interchangeably, they are distinct approaches with unique focuses and applications.
In this blog, we’ll explain the similarities and differences between these two approaches to process improvement, and explain why a Lean approach is ideal for members of the design and construction industry.
What is Six Sigma?
Six Sigma, originally developed by Motorola in the 1980s, is a data-driven method to improve quality by minimizing defects and variations in any process. By striving for near-perfect quality, Six Sigma seeks to achieve a defect rate of no more than 3.4 defects per million opportunities.
The methodology follows a structured approach known as DMAIC, which stands for Define, Measure, Analyze, Improve, and Control. Each phase of DMAIC involves specific tools and techniques to systematically address quality issues and enhance process performance.
What is Lean?
Lean, inspired by the Toyota Production System, is a management philosophy centered on maximizing customer value by systematically eliminating waste and refining processes. This approach emphasizes continuous improvement and deeply values respect for people, creating a culture of collaboration and proactive problem-solving.
By targeting the elimination of the eight wastes—defects, overproduction, waiting, non-utilized talent, transportation, inventory, motion, and extra-processing—Lean optimizes workflows, shortens lead times, and enhances overall efficiency.
Understanding the Difference Between Six Sigma and Lean
While both Lean and Six Sigma strive for process improvement, their primary focuses differ. Six Sigma concentrates on reducing variations and defects to enhance quality, while Lean prioritizes waste elimination to improve efficiency and flow.
In the context of design and construction, Six Sigma can be applied to ensure consistent quality in building materials, construction techniques, and project delivery. Lean, on the other hand, can be used to optimize project schedules, minimize material waste, and improve communication among stakeholders.
Why is Lean Ideal for Design and Construction Professionals?
Lean is ideal for design and construction professionals committed to transforming project delivery by maximizing value and minimizing waste across all project phases. It empowers teams to collaboratively plan and execute work in a way that aligns with customer-defined value, enhances efficiency, and reduces unpredictability.
By emphasizing reliable commitments, continuous improvement, and respect for people, Lean Project Delivery fosters a culture of trust and shared responsibility. This approach enables professionals to achieve better project outcomes, delivering projects that meet or exceed client expectations.
The Main Benefits of Adopting a Lean Mindset
Lean offers numerous benefits for professionals in the built environment, including:
Increased Value to the Customer
Lean design and construction focuses on delivering exactly what the customer needs, when they need it, without added steps or red tape. This results in higher satisfaction and increased value that’s better aligned with what the customer is looking for. Increased communication through Lean methods can also lead to heightened innovation.
Improved Schedule Performance
Lean methodologies help project teams coordinate workflows and improve efficiency, allowing projects to be completed on time or even ahead of schedule.
The increased communication between project teams allows those teams to better plan handoffs, which reduces waste such as long wait times between tasks or materials not arriving in the right place at the right time.
Enhanced Productivity
With decreased waste, team members can accomplish more in the time they have on the jobsite. This allows workers to feel more fulfilled in their work and leads to fewer late days on the jobsite so workers can go home on time and reduce the amount of overtime hours worked.
Smoother Problem Solving
Key Lean methods such as A3 thinking and root cause analysis allow for swifter, collaborative problem solving. Lean also encourages continual learning and documentation, decreasing the instances of bottlenecks or stoppages in the future.
Increased Worker Satisfaction
Lean emphasizes a mindset of respect for people, which encourages collaboration and professional development for all workers. When you work in a Lean environment that fosters a more positive and engaging work environment, worker satisfaction increases and innovation flourishes.
Safer Job Sites
With greater organization, improved lines of communication, and reduced waste in the workflow, projects that utilize Lean principles create safer job sites with fewer accidents. By working fewer overtime hours, project team members will also be more energized and alert on the jobsite.
Improved Profitability
Projects that utilize Lean methods complete a higher percentage of weekly tasks and produce lessened waste, leading to increased profit margins for team members and owners alike. The schedule planning that takes place on a Lean jobsite also adds an additional layer of cost certainty.
Become a Lean Practitioner: Learn From the Lean Construction Institute
Embark on your Lean journey and unlock the full potential of your construction projects. The Lean Construction Institute offers a wealth of resources, training programs, and certifications to help you master Lean principles and practices.