Six Sigma Principles: Exploring Six Sigma, Lean, and The 5S System

Six Sigma is a systematic approach to eliminating errors that harmonizes with 5S and 5S principles. This quality improvement approach uses statistical methods to improve quality by minimizing variability in business processes, from just-in-time manufacturing to engineering and purchasing. Six Sigma and Designing for Six Sigma accomplishes its goal by using two Six Sigma Methods: DMAIC and DMADV.  

What Are the Two Core Six Sigma Methods?

Six Sigma uses two primary methodologies: DMAIC for improving existing processes and DMADV (Design for Six Sigma) for creating new ones. Both rely on data-driven decision-making and structured steps to reduce variability. The Six Sigma DMAIC approach is typically used to improve an existing lean manufacturing process.

Improving Existing Processes with DMAIC  

DMAIC is an acronym that stands for:

• Define the problem and desired outcome
• Measure the ability of the process
• Analyze the data and identify the root cause of variations (defects)
• Improve or modify the 5s audit process so that fewer variations (defects) are produced
• Control the process. Prevent and correct variations before they result in defects
  

DMAIC pairs well with 5S labels for manufacturing efficiency, helping teams track performance visually and correct errors in real time. It brings structure to continuous improvement efforts and reinforces operational discipline. When a process needs to be built from the ground up, not just improved, a different approach is needed.

Designing New Systems with DMADV 

When designing a new process, the Six Sigma DMADV is used. It is also known as DFSS (Design for Six Sigma). The DMADV acronym stands for:

• Define design standards that align with the product or process goals
• Measure and identify characteristics of the product or process that are critical to quality
• Analyze the data, and identify possible sources of defects
• Design changes that will eliminate the source of defects or errors
• Verify that the design will meet the requirements

DMADV helps ensure that new workflows are lean, scalable, and built to avoid future variation. But building a sustainable system takes more than just a method, it requires the right mindset. That’s where Lean principles come into play.

What Principles Support 5S and Six Sigma?

Whether you're streamlining production or redesigning a serviced workflow, 5S is grounded in five Lean Six Sigma principles: 

• Focusing on customer requirements
• Using extensive measurement and statistical analysis to understand how work gets done and to identify the root cause of problems (variations)
• Being proactive in eliminating variation and continually improving the process
• Involving people in Six Sigma cross-functional teams
• Being thorough and flexible

These principles drive every successful Six Sigma initiative and create a foundation for long-term success.

How Do You Identify Root Causes in Six Sigma? 

To correctly identify a root cause, a complete understanding of the process is necessary. This does not mean just understanding how a process was designed to work. It means understanding how the process is actually working. To accomplish this you need to:

• Have clearly defined goals for data collection
  • Identify the data that needs to be collected
  • Have a defined reason for the data being collected
  • Establish what insights are expected from the data
• Ensure accurate communication by clearly defining terms
• Ensure that measurements are accurate and repeatable
• Establish a standardized data collection system/process

Once the data is collected, determine whether it is providing the required insight and is meeting the goals that were established. If not, refine the data collection plan and collect additional information.

Data collection involves interviewing people, making observations, and asking questions until the answers are found. Ask the questions such as:

• "Why do we do things this way?"
• "What would make your job easier?"
• "What things do you do that seem to be a waste of time?"

Once the data is collected, use it to look for ways to improve or optimize the process by identifying the root cause of variation. Using tools like Value Stream Mapping and 5 Whys, teams can isolate true causes—not just band-aid fixes—and feed that insight back into 5S systems, visual cues, and process controls.

Why is Eliminate Variation So Important?

Inconsistent processes create inconsistent results. Six Sigma’s goal is to reduce process variation, which in turn reduces defects, waste, and inefficiency.

After identifying root causes:

• Remove steps that don’t add value for the customer

• Adjust or eliminate inputs causing instability

• Introduce visual cues—like 5S labels for manufacturing efficiency—to reinforce consistent behavior

• Monitor performance continuously using tools like Statistical Process Control (SPC)

This mindset of proactive problem-solving helps organizations stay ahead of issues instead of reacting to them after the fact. Don't wait for signs of variation to become obvious. Collect data, talk with people, and study the data to find variations in the process that may have become accepted because "that's the way we've always done things."

Teamwork

This quality improvement system involves teams and leaders who take responsibility for the processes and strive to apply 5S principles into their workplace. The people on the teams need to be trained in Six Sigma's methods, including the measurement methods and improvement tools that will be used. In addition, they need communication skills so that they can involve, serve, and communicate clearly with both coworkers and customers.

Putting together teams that have members with a variety of skills and backgrounds related to a process will help the team spot variations. For a manufacturing process for example, people from operations, maintenance, engineering, and purchasing should be included.

Be Flexible and Thorough

Six Sigma requires flexibility in many ways. The business's lean management system needs to accept positive changes as well as empower change. Employees should be motivated to adapt to change. In the beginning, the benefits of the changes should be made clear to workers. This will help to create an environment where change is more readily accepted.

A key to this continuous improvement framework is the ability to change or adapt procedures as needed. For instance, lean and visual communication systems, such as Andon or Heijunka Box, although not common in the Six Sigma process, can and should be added and adapted to if and when they work. In short, the process required for change should not be so complex that workers and management would rather work with a broken process than fix it.

Six Sigma also requires problem-solving to be thorough. Making sure to understand every aspect of a process, including the steps, people, and departments involved will help to ensure that any new or updated process works.

What Tools Help You Apply Six Sigma?

Six Sigma uses a variety of tools to support root cause analysis, process control, and visual problem-solving, including Value Stream Mapping (VSM), Capability Analysis, 5 Whys, Plan-Do-Check-Act (PDCA), and Statistical Process Control (SPC).

• VSMs: Flowcharts that enable businesses to understand every aspect of a process and define potential problems. Unlike standard flow charts, VSMs include the internal (departments and workers) and external (customers and shipping) factors that affect a process. By completely mapping out a process, it is much easier to define potential problems.
• Capability Analyses: Measures the ability of a process to meet a business's needs. This tool allows businesses to quantify the relationship between the customers' needs and the current process's ability to meet those needs, allowing businesses to make customer-focused processes.
• Five Whys: Enables businesses to hone in on a problem's root cause and fix it, rather than addressing surface-level issues that temporarily improve a situation. Doing what its name suggests, Five Whys requires workers to ask "why" until the root cause of a problem is identified.
• PDCA: A cycle for designing and testing improvements. It solves problems using four steps: Plan, Do, Check, Act. Once a root cause is identified, this tool allows it to be addressed systematically by creating a solution, testing it, reviewing its success, and finally implementing it.
• SPC: Monitors and controls variations over time by tracking its metrics. A common way to implement SPC is to use a control chart, which records information and allows businesses to see when a process stops working. Once an issue is discovered, the process can be altered to solve any new problems that occur.

DuraLabel Six Sigma Resources

Six Sigma involves change, and change requires effective on-going communication. Old habits need to be broken, and new habits established. DuraLabel offers an array of supplies that can help make this quality management system successful in your business including printers and labels.

Whether you need safety signs, pipe markers, or equipment labels—DuraLabel® Toro® Max Industrial Sign and Label System and DuraLabel® Kodiak® Max Industrial Sign and Label System​ are ready to transport anywhere you are. Get help crafting a system that will provide the safety communication you need. Call 1-888-965-3359 and one of our experts will guide you through the process. 

Want to apply Six Sigma principles to your workplace? Learn more about how lean tools can be used to help create an environment where changes are accepted and business practices are continuously improved upon. Download our free 5S Quick Start Guide. 

Need help getting started? Call 1-888-788-9936 to speak to a DuraLabel expert and build a system that supports your lean goals.