LEAN SIX SIGMA

We implement Lean Six Sigma as a method for expert projects within the lean business systems we create. Lean Six Sigma is a holistic, customer-oriented improvement and problem-solving methodology. The goal of Lean Six Sigma is to achieve outstanding performance in process organization with the aim of groundbreaking improvements within a short period of time. Lean Six Sigma is a key competency for reducing variation, defects and costs.

Services

Lean Six Sigma is a service package that we tailor to the individual requirements of your company. This way, you get the implementation that fits your company, your strategy and the people in your company like a tailor-made suit:

• Implementation Management – We support you in evaluating the requirements, planning, setting up and further developing the system and structures for your company to improve on the basis of Lean Six Sigma.

• Training – Expert projects require specific training for project leaders and managers involved. Our training program includes qualifications for all Lean Six Sigma qualification levels. This will help you to optimally increase your employees’ problem-solving skills and give your own implementation of Lean Six Sigma the right impetus.

• Coaching – Our experts support your project managers and teams in the implementation of demanding optimization projects with Lean Six Sigma. This significantly increases the efficiency and speed of your projects and initiatives.

• Certification – We offer appropriate certifications for the training program to ensure the quality standards for your implementation of Lean Six Sigma. We will work with you to design an internal certification program so that your employees receive meaningful proof of their skills.

• On-site project implementation – Our experienced experts lead projects and develop solutions for your challenges directly with your teams on site. This ranges from individual workshops to quickly implemented small projects or a demanding transformation of entire value streams.

Lean Six Sigma is based on a holistic methodology and functioning shop floor management. In this sense, we only use the tools and methods that are really needed in the company. Measurable results, sustainability and acceptance of the solutions are always the focus of our projects.

Impact

A Lean Six Sigma project should be directed at a key problem/topic with the aim of significantly improving operational performance. In each project, the financial benefit is shown alongside the operational benefit. The duration of a Six Sigma project ranges from 3-4 months (Green Belts) to 5-6 months (Black Belts), depending on the scope of the process.

For our customers, we are a powerful partner on the way to top performance. The return on investment (ROI) of our projects is usually above a rate of 1:5. Overall, we have achieved confirmed financial successes of more than EUR 550 million with our customers in more than 800 projects carried out and supported.

DMAIC is a phase-oriented approach to problem solving:

• Define: The problem or issue is scoped and defined precisely and in a customer-oriented manner. Customer requirements are analyzed and understood.
• Measure: The process is mapped in detail, the key parameters along the process are measured and the measurement system is validated. The initial state of the process performance is determined.
• Analyze: Cause-effect relationships are derived and, if necessary, verified using statistical methods. The result of the analysis phase is knowledge about the vital few key influencing factors in the process and the causes of deviations.
• Improve: Measures are developed and implemented in the team for the key causes of variation in the process or to increase the value contribution.
• Control: The results achieved are designed in such a way that employees can stabilize the results independently even after the end of the project.
• Sustain: After the project has been completed, the results are tracked over a longer period of time, but at least 12 months. In the event of deviations, countermeasures are taken.

Training & Certification

Our training offer as an in-house training program covers all qualification levels of the Lean Six Sigma methodology. For the Green Belt and Black Belt levels, the processing of corresponding projects or the implementation of workshops is necessary in addition to the training. We conduct our training courses based on various software for statistical evaluations. We currently support Minitab and Sigma Magic.

We provide training programs for the following levels of proficiency with Lean Six Sigma:

• Champion – Project Sponsors
• Black Belt – Project leaders with expert level qualification for high impact projects in a dedicated semi-dedicated role
• Green Belt –Project leaders that implement improvements within their function in part-time
• Yellow Belt – Qualified team members that support Green and Black Belts in their projects

For each qualification level, a detailed description of the role’s tasks, the content of the training and the scope of services is available. In addition to training courses, we run champion workshops for management and board members as well as functional leads.

Certification by the AMELSBERG GROUP confirms the knowledge, experience and results of your employees and documents successful qualification. For Green Belts and Black Belts, it consists of a theoretical examination and the acceptance of the respective successfully completed projects.

We support our customers in setting up internal certification programs and, as an external partner, take on some of the associated content and administrative work. Internal certification makes the certificate particularly useful as recognition of what has been achieved.