Which could be more useful to the operational and tactical levels, Lean or Six Sigma?

2022-11-03T14:44:26-04:00

For those unaware, Lean and Six Sigma are schools of thought in today's business industry, both relatively modern. They're focused on decreasing waste and maximizing gains. Various certifications are available and most of them are recognized and covered through the Army's Credentialing Assistance (CA). There are even certifications available that combine both schools of thought, cleverly known as "Lean-Six Sigma". My questions implies a couple of things from its response: 1) Which ideas should the Army take to heart, 2) Which ideas should individual leaders be studying?

Maybe the hybrid option is the best option, if any at all. Does anyone have experience with these or opinions one way or the other?

I am leaning towards pursuit of a Lean-Silver certification. I dipped my toes into Six-Sigma somewhat and was not interested. Personally, I am looking for lessons that can be incorporated into small teams, switching between the bigger and smaller pictures with ease in down-to-earth operations that are strictly people-first but laser-focused on the mission and the commander's intent.

How many of us have gone into the S-Shops in today's Army and seen absolute chaos? I have personally ridden that lightning. Most of us know that the Army already has a vulnerable system; a comparatively bloated staff to the other branches that in times of war, can become a huge behemoth of logistics and data that is sometimes as much a hindrance as it is a benefit. Mattis and his writings about the invasion into Iraq come to mind. I think one of these programs could help sharpen my mind and benefit the Army is resisting some of this. I am thinking long-term benefits here.

Reading:
https://www.army.mil/article/188090/army_recognizes_best_lean_six_sigma_initiatives

Army recognizes best Lean Six Sigma initiatives

Saving millions of dollars, the recipients of this year's Lean Six Sigma excellence awards reduced processing times, improved health of the force and increased readiness.

Response by COL Randall C. made Nov 3 at 2022 2:51 PM

2022-11-03T14:51:50-04:00

The Army, Navy and Air Force have invested heavily in Lean Six Sigma (LSS) for the last ~15 years or so. The Army even stood up a PMO for its implementation (you know the Army is serious about something if it stands up a PMO and throws resources at it).

Response by 1SG Russell S. made Nov 3 at 2022 8:26 PM

2022-11-03T20:26:50-04:00

The US Military using Lean Six Sigma is a paradox. Spending all budget lines so none are cut the next FY; DRMO; deployments to Kuwait; the new M5; etc…….the military is a poster child of waste fraud and abuse of time, items and people.

Response by LTC Private RallyPoint Member made Nov 3 at 2022 9:14 PM

2022-11-03T21:14:39-04:00

The Army actually has an excellent Lean Six Sigma credentialing program of its own.

Response by CSM Darieus ZaGara made Nov 4 at 2022 6:17 AM

2022-11-04T06:17:53-04:00

Not to be contrary, they are not new, they have been around for decades. Like any theory, process, program, education they are valuable. What has to be weighed is how do they fit into your person and organization.

There is much of many different programs and strategies that are fully integrated into your military training and programs.

My point I guess is that there is no single golden ticket, rather an amalgam of multiple processes which helps to elevate you as a person, a peer and a leader. Whatever works best for you.

Response by CSM William Everroad made Nov 4 at 2022 11:25 AM

2022-11-04T11:25:55-04:00

1LT Private RallyPoint Member, senior leaders are already encouraging their mentees to do both. Especially in Engineering, there are benefits to being exposed to the principles of Lean and Six Sigma.

This early in your career, my advice would be to get both certifications. They aren't difficult to obtain. The hard part is figuring out how to apply what you learn in your jobs. Then you can go for the hybrid or advanced certifications.

Your point of "looking for lessons that can be incorporated into small teams" is great now, but as you move through the echelons, you are working with bigger and bigger teams with more convoluted processes that are in dire need of efficiency reform (learn about the military decision making process before proposing sweeing reform). Lean would be my focus as Six Sigma is aimed at process improvement to reduce errors, like I said the hard part is connecting it to your job.

You can try to fight staff bloat, but when you are a BN or BDE CDR, you will welcome the agility of a larger staff during high operational tempo.

Response by SFC David Reid, M.S, PHR, SHRM-CP, DTM made Nov 4 at 2022 4:44 PM

2022-11-04T16:44:16-04:00

I would suggest Lean, instead of Six Sigma!

Response by Lt Col Jim Coe made Nov 7 at 2022 10:25 AM

2022-11-07T10:25:24-05:00

As COL Randall C. points out, Army had a Lean Six Sigma program during the mid-2000s. It declined in popularity and resources and changed names a couple of times by 2015. I was a LSS program manager for SDDC in this timeframe. Also an Army certified Black Belt.

To answer your question, I think Lean would be most beneficial at the operational and tactical level. The Lean focus on process improvement and continuous improvement works well in a staff work environment. However, some SixSigma data analysis is necessary to show the value of changes to leadership.

I liked the LSS project management approach following the DMAIC (define, measure, analyze, improve, control) process. The Project Management Institute’s approach of develop, plan, execute, control, evaluate can also be used.

No matter what process you use change is difficult. Make sure you have support from senior management and the commander before you start.

Response by GySgt Kenneth Pepper made Nov 7 at 2022 2:28 PM

2022-11-07T14:28:21-05:00

I was certified as a Lean Six Sigma Green Belt shortly before retiring in 2008. My certification project was focused on streamlining a helicopter engine repair/test shop. Because the before process was so bad, it was an easy win. Number of engines pulled vs. the time to repair and replenish equals the number of assets required to be ready at any given time. Instead of 3 different crews each working on one at a time, we established a one piece flow. Worked really well, but not at what I would refer to now as a Lean Six Sigma project.
Fast forward, I am certified as a LSS Master Black Belt. I have used most of the tools associated with LSS on different projects with great success. The DMAIC process is great. But it has to be followed precisely. No assumptions.
As far as how the tools could be used in the military I think Lean, Theory of Constraints and 5S would be sufficient.
I usually explain it like this; Lean is a chainsaw, Six Sigma is a scalpel. Use Lean, ToC and 5S to go after the low hanging fruit. Use Six Sigma to get that last 5% remaining after the waste has been trimmed off.
If you are interested, I suggest Villanova's certification program.

Response by COL Bill Gross made Jan 29 at 2023 4:50 PM

2023-01-29T16:50:45-05:00

I joined US Army North, Fifth US Army in my final career this time as a DAC. CG 5A was fully on board with it. He really pushed it. Ten years later if you asked anyone around Army North HQ, you might find someone how had a binder with Six Sigma on the cover. It has gone the way of the latest, greatest new ideas that I have seen come down the road, then turn around and go back where it came in over fifty years.

You may color me cynical about any of these programs. If you really want to pursue it in the context of the US Army, find some shop that still clings to it and ask folks there your questions.