I loved reading Goldratt’s The Goal.
In Velocity, the same authors attempt to make simple, through narrative, one of the most widely respected and adopted frameworks for fixing broken processes and improving quality—Lean Six Sigma. This approach blends the waste-reduction focus of Lean with the precision-driven quality control of Six Sigma. Together, they offer a powerful set of tools and principles that help organizations cut costs, raise standards, and deliver better results with fewer headaches.
SIX SIGMA
Developed at Motorola in the 1980s, Six Sigma is a data-driven system for improving quality by identifying and eliminating flaws in business processes. At its core, Six Sigma aims to minimize defects – anything that fails to meet customer expectations, whether that’s a late delivery or a faulty part. The benchmark is ambitious: fewer than 3.4 defects per million opportunities. Achieving this requires a deep focus on statistical analysis, especially standard deviation – referred to as sigma – which measures how much variation a process produces. The lower the variation, the more consistent the outcome.
Six Sigma uses two structured improvement models. DMAIC – Define, Measure, Analyze, Improve, and Control – is used to fix existing processes by identifying root causes and making sustainable changes. DMADV – Define, Measure, Analyze, Design, and Verify – is for creating new processes or products, building in quality from the start.
While Six Sigma focuses on precision through data, Lean takes a complementary approach – targeting waste and inefficiency to streamline how work gets done.
LEAN
Lean production is a method built around a simple question: Where is effort being wasted? Instead of squeezing more out of people or equipment, it focuses on eliminating anything that doesn’t directly contribute to customer value. Originally developed from the Toyota Production System, it’s a flexible approach used far beyond car manufacturing – in hospitals, offices, and tech companies – wherever efficiency and quality matter.
At the core of Lean are three types of waste: physical waste, uneven workflows, and overloaded systems. These are known by their Japanese names – muda, mura, and muri. Muda refers to wasteful activities that add no value, like overproducing goods or waiting for parts to arrive. Even underused employee skills are counted as waste, not because they slow production down, but because they represent missed chances for innovation and improvement. Mura is about inconsistency: when work arrives in unpredictable bursts, it causes delays and downtime. Muri means asking too much of people or machines, which can lead to breakdowns or mistakes.
Lean is about building a culture of continuous improvement, known as kaizen. Instead of chasing big, sweeping changes, kaizen encourages steady, small-scale updates to how things are done. This can involve everything from redesigning a workstation to changing how information flows through a team. It’s supported by a method known as PDCA: Plan, Do, Check, Adjust – a cycle that helps teams test ideas, measure results, and make refinements part of everyday work.
Simplicity plays a big role, too. The fewer moving parts in a process, the easier it is to monitor, maintain, and improve. Lean also depends on visibility: unless waste can be seen and tracked, it’s unlikely to be addressed. That’s why clear layouts, open communication, and responsive supply chains are essential. Altogether, Lean provides a structured but adaptable way to reduce waste, improve quality, and keep businesses agile and competitive.
CHALLENGES
Six Sigma, in particular, has been criticized for being highly specialized and sometimes disconnected from broader business needs. It works best with well-defined, repeatable processes but struggles in creative or less structured environments like marketing or product design. The training requirements are steep, and advanced roles often demand full-time attention to Six Sigma projects. For smaller businesses, that kind of time and resource commitment may simply not be feasible. Bringing in external consultants can help, but not every company is willing or able to take that route, and without skilled guidance, adoption can stall. Even among staff, the system’s statistical foundation can seem overly complex or intimidating without proper context and communication.
Lean comes with its own challenges. The core idea – reducing waste and improving flow – sounds simple, but implementation can easily fall flat if it's driven only from the top down. When frontline workers aren’t involved in identifying problems and solutions, improvements tend to be superficial. Another issue is that some organizations approach Lean like a fixed recipe, expecting every tool to work in every situation. But Lean’s real strength lies in tailoring its principles to fit the unique shape of each business. The same goes for culture. The most effective Lean programs embrace kaizen – that belief in steady, continuous improvement. Skipping this and just applying tools without that mindset misses the point – and the potential.
REVIEW:
While I admire their attempt at helping readings transfer lessons from other people’s experiences, this is only the first step required to deeply understand LSS enough to apply it in your own context. (Note: not all steps apply. But the principle of Kaizen, or continuous improvement, is forever.)