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Lean Six Sigma Consulting

What Is Lean Six Sigma?

Lean Six Sigma (LSS) combines the popular process improvement methodologies, Lean and Six Sigma. Lean principles were inspired by the Toyota Production System, which was a manufacturing philosophy aimed at eliminating waste and increasing efficiency. One of its central concepts is just-in-time inventory management, which focuses on ordering only what’s needed from suppliers as it’s required to meet production schedules.

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Six Sigma is a business process methodology with roots at Motorola. It aims to identify and eliminate defects. Six Sigma takes a statistical approach to problem-solving, analyzing and reducing variations.

The main goal of Lean Six Sigma, which was introduced to the business world around the turn of the century, is to increase performance through eliminating waste and defects. Since its development, Lean Six Sigma has been successfully integrated into a vast range of industries, from aerospace to healthcare. 

What Does a Lean Six Sigma Consultant Do?

Generally, a Lean Six Sigma consultant trains, advises, and certifies organizations on LSS methods. At Business Transformation Institute, Inc., we implement Lean Six Sigma as a data-driven, fact-based method of achieving organizational goals, including increasing customer satisfaction, reaching corporate financial targets, and measurably improving quality. We do this by helping businesses implement the best workflow or process to diminish waste while reducing variation, cycle time, and rework.

As process improvement experts, we understand that a one-size-fits-all approach doesn’t work when implementing Lean Six Sigma. While we leverage our experience with clients in various industries, we know that each organization is unique. We’ll evaluate your business’s processes and your customers’ expectations carefully and then devise a strategy that’ll bring quantifiable benefits.

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Our Lean Six Sigma Consultation Services

We’ll help your organization implement Lean Six Sigma in two ways:

1. Deploy Our Certified LSS Black Belts

We’ll deploy our Lean Six Sigma Black Belts, certified by the American Society for Quality, to:

  • Improve your existing processes with the LSS define, measure, analyze, improve, and control (DMAIC) methodology.
  • Create and implement new processes using the LSS define, measure, analyze, design, and verify (DMADV) methodology.

2. Help You Create and Sustain a Companywide LSS Culture

Our experts will help your company develop, launch, and maintain a Lean Six Sigma culture throughout your organization. We’ll train your managers, quality assurance staff, and process improvement personnel on LSS concepts. We can also train personnel to utilize LSS tools and apply LSS concepts to real-world applications. Teaching your leaders about Lean Six Sigma prepares them to integrate its principles into your organization’s infrastructure, transforming how you “do business.”

What Are the Benefits of Hiring BTI as Your Lean Six Sigma Consultant?

BTI can provide many benefits as your Lean Six Sigma consultant, including:

1. Cost Savings

We apply Lean Six Sigma in a way that has consistently yielded substantial savings for our customers. We want your company to be among those that have achieved lower operational costs through LSS.

Lean Six Sigma has helped major corporations save millions and, in some cases, billions of dollars. For example, Honeywell (AlliedSignal) saved over $800 million implementing Six Sigma, while GE saw $12 billion in savings over five years due to applying Six Sigma principles.

We have helped government organizations and businesses of all sizes enjoy remarkable savings year after year.

2. Increased Productivity

All organizations have room for improvement — no matter how efficient they may be. Utilizing Lean Six Sigma tools such as Poka-Yoke, also called mistake proofing, and analyzing value-added and non-value-added activities can help you fix process problems, boost your process efficiency ratio, reduce rework, and make you more competitive. The goal is always to do more while investing the same or less.

3. More Predictable and Shorter Cycle Times

Understanding and controlling common cause variation and finding and eliminating the root causes of particular cause variation is the heart of Six Sigma techniques. Once you start using LSS tools to recognize and control variation, you can say goodbye to frequent project deadline overruns. Working with BTI consultants, your team will quickly identify and eliminate process performance issues that lead to unpredictable project cycles.

4. Decreased Defect Rates and Cost of Poor Quality

High defect rates mean higher rework, scrap, or repair costs — all contributing to Cost of Poor Quality (COPQ). According to the American Society for Quality, many successful companies have a COPQ of 10 to 15% of their operations, but this number could be lower. LSS can help your organization decrease its defect rate to fewer than 3.4 defects per million opportunities. We’ll help you apply Lean Six Sigma tools like 5S, work-in-process reduction, and mistake-proofing to lower the number of defects.

5. Improved Customer Satisfaction

A key aspect of LSS implementation is embedding it into your organization’s culture. When LSS is woven into your company’s culture, everyone will be equipped with the necessary tools to recognize and reduce variation and waste, all while understanding the return-on-investment relationship between your processes and how your organization defines success.

Training your people is central to achieving a Lean Six Sigma culture. Through our LSS training program, your employees can achieve White Belt and Green Belt status. This will empower them to become better problem solvers. They’ll quickly start using new skills to improve processes, leading to enhanced efficiency, quality, and delivery predictability, as well as happier customers.

Why Is BTI Your Best Choice for Successful Lean Six Sigma Consulting?

You can count on us to provide effective Lean Six Sigma consulting. Here’s why:

  • We practice what we preach.
  • We provide measurable results.
  • We use leading-edge techniques, like process mining.
  • We’ve done this for over a decade.
  • We’re professional and thorough.
  • We’re certified trainers.
  • We focus on you and the results you want.
  • We help you save time and money.

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How Do We Offer Our Lean Six Sigma Consulting Services?

1. Training:

We offer three training courses for Lean Six Sigma to help you incorporate LSS into your organization’s culture:

  • White Belt: Our one-day White Belt training course introduces students to Lean Six Sigma techniques and culture. The course is suitable for employees who want to learn LSS basics but may not be on an LSS project team. White Belt training can also prepare employees for Green Belt training.
  • Green Belt: This course trains and certifies your team to work on Lean Six Sigma projects, teaching them the necessary statistical skills for process improvement. The course prepares students for the American Society for Quality Green Belt certification test.
  • Black Belt: This course trains and certifies the craft masters and knowledge leaders of Lean Six Sigma projects. Its content prepares students for the American Society of Quality Black Belt certification test.
  • Lean Six Sigma for Engineering: This class is for those who need to learn the principles and methods used to design, develop, and implement engineering products, like software, hardware, and systems, in a Lean Six Sigma culture. The course is helpful for organizations implementing a DevOps life cycle.

2. Consulting and Implementation Support:

BTI consultants are LSS Black Belts certified by the American Society for Quality. We will help your organization reach its goals for quality, productivity, and efficiency using Lean Six Sigma’s two improvement strategies — DMAIC and DMADV.

DMAIC is an acronym used for the five phases of a data-driven quality and process improvement strategy for existing processes. We use this in our Lean Six Sigma strategy for all-around process improvement. The five phases are:

  • Define: Create a detailed specification of the problem, project scope, improvement activities, project goals, and customer requirements.
  • Measure: Develop well-defined metrics to measure and record process performance.
  • Analyze: Perform a careful study of the process to discover the principal causes of defects and variations.
  • Improve: Boost the performance of the process by dealing with and removing root causes.
  • Control: Monitor and modify the improved process and enhance future process performance.

DMADV is an acronym used for the five phases of a data-driven quality and process improvement strategy for new processes. The five phases are:

  • Define: Define the project goals and customer needs.
  • Measure: Measure and determine customer needs and specifications.
  • Analyze: Determine the process options.
  • Design: Develop the details for producing a process that meets the customers’ needs.
  • Verify: Verify the design against the requirements and validate it with customers.

Contact Our Team Today

At BTI, our Lean Six Sigma experts are fully prepared to help you enjoy the many benefits of this process improvement technique. Give us a call today to discuss your needs and get a free consultation.

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    Here’s What Our Clients Are Saying About Us

    BTI succeeds in its mission when an organization is measurably better in a way that makes a real difference, is able to sustain the change for the better, knows that it is better, and is satisfied with the result.

    Business Transformation Institute, Inc. (BTI) joined in partnership with Raytheon SAS to help us bring together many diverse business units and to stabilize and improve our performance.  Throughout the years we have worked together and achieved CMMI Maturity Level 5 while bringing together geographically and process diverse units. This has allowed us to have a much higher fluidity in our staff and contract execution locations without suffering performance degradation.  Also, BTI has led the way in choreographing novel appraisal methodologies that have significantly reduced the cost of maintaining CMMI certification and ensuring that the programs do not suffer “set-back” during the gap between certification renewals.

    Alan Perkowski 1 E1695234482260

    Alan Perkowski

    Process Maturity Technical Director from Major Aerospace Company

    Having BTI’s LSS black belts onboard means that I can now safely retire.  Thank you!

    Lean Six Sigma Master Black Belt

    Lean Six Sigma Master Black Belt from National Security Agency

    CNI was going to graduate from the federal government’s 8(a) program.  We had to be prepared to compete. Part of this is having good processes.  BTI helped us to do it.

    Phil Ricks 1 E1695234421930

    Phil Ricks

    Corporate Quality Manager from Chickasaw Nation Industries

    I was fortunate to work with the BTI team on deploying the CMMI Level 2 practice at Western Union. There were a number of obstacles in garnering top-down changes and support everyone that the team was able to work through and make it successful.

    Implementing CMMI practices and procedures in an unstructured environment is surely difficult, but the BTI team was able to see the big picture and also make sure that the details were correctly addressed and implemented.

    I highly recommend the BTI team!

    John Oyhagary 1 E1695234675445

    John Oyhagaray

    Western Union Systems Development