lean consulting

Six Sigma, or its newer offspring Lean Six Sigma (LSS) is a comprehensive and highly disciplined methodology that helps us focus on developing and delivering near-perfect products and services, by analyzing the underlying business processes and preventing and / or removing defects before reaching the customer. LSS also is a wide range tool set that is used under organized the following “problem-solving” quasi sequential steps:

  • Define –some of the deliverables in this step are project charters, CTQs, house of quality, kano models;
  • Measure – statistical descriptive and graphical tools, process and value stream mapping, capability analysis, data gathering tools;
  • Analyze –statistical analysis tools, brainstorming, Pugh matrices, House of Quality (QFD),FMEA, Muda;
  • Improve – Pugh matrices, mistake proofing, 5S, design of experiments;
  • Control – Process Control plans and Statistical Process Control (SPC)

Lean has been described many different ways. Typically we use Lean when we are looking to quickly provide value. It is especially helpful in service organizations. In Lean we stream line by identifying a) what is critical to the customer b) what is the value stream of the core processes and c) how do we align the voice of the customer and the voice of the employees toward common goals. LSS is a combination of the Six Sigma Improve and Lean tools such as the 5S which is the abbreviated reference to five Japanese words that govern workplace organization and housekeeping. The five words are: Seiri, Seiton, Seiso, Seiketsu, and Shitsuke.

Typically this results in 8 types of waste / non-value added work

  1. Wasted human talent – Loss of intellectual capital
  2. Defects – “Stuff” that’s not right & needs fixing
  3. Inventory – “Stuff” waiting to be worked
  4. Overproduction – too much/too early “Stuff”
  5. Waiting Time – People waiting for “Stuff” to arrive
  6. Motion – Unnecessary human movement
  7. Transportation – Moving people & Moving “Stuff”
  8. Processing Waste – “Stuff” we have to do that doesn’t add value to the product or service we are supposed to be producing
the five steps in lean practice include:
  1. Identifying Value
  2. Defining Value Stream
  3. Determining Flow
  4. Defining Pull, and
  5. Improving Processes

One of the complaints of Lean is that it cannot bring a process under statistical control so this is where Six Sigma Lean -especially the control phase- can assist. Conversely, one of the complaints of either Six Sigma path is that it takes too long. We customize both Six Sigma and Lean tools to get the greatest value for our customers.

Regardless of the Six Sigma and/or Lean Path you chose, Metaspire has:

  • Certified Six Sigma professionals
  • Certified Lean professionals and
  • Certified Lean Six Sigma professionals

Request your assessment today to see how Lean Six Sigma can improve your company.


Organizational Development support for an extensive Capability Maturity Model Integration benchmarking project that identified $200 Million in technology savings by restructuring software development processes. We received assistance tying together leadership roles, and processes.

-- Daniel Bovarnick, Former Director Technology Global Reengineering American Express