As a manufacturer, if you’re not doing everything you can to improve your productivity, you risk falling behind your competitors.
For those who want to push their business performance to the next level, there are few better investments than bringing the data-driven and action-oriented approach of Lean Six Sigma (LSS) process improvement to your organization. With the help of a certified and tenured LSS consultant, implementation of sustained process improvements minimizes improvement failure with the best practice approach, tools and techniques…
Building a culture of continuous improvement isn’t easy, but hiring the best LSS consultant for your team will bring the knowledge and skills that will help you streamline production and elevate your business performance.
Today, Manex will guide you through selecting the right LSS consultant for your company’s needs and discuss what questions you need to consider.
What Does a Lean Six Sigma Consultant Do?
Lean Six Sigma is one of the world’s leading process improvement methodologies. Used across industries, it brings a data-driven and action-oriented approach to improving business performance, quality, and productivity by identifying and eliminating the waste or root causes of defects in manufacturing or business processes.
Many organizations choose to hire a LSS consultant to help them strategically and tactically apply the principles to their own workplace.
Lean Six Sigma consultant services often include:
- Working directly with leadership to identify, plan, and drive improved productivity
- Process mapping and value stream analysis
- Identification and elimination of waste, variations, and defects
- Implementation of DMAIC projects (Define, Measure, Analyze, Improve, Control)
- Training and certifying internal teams
- Measuring performance and keeping teams accountable
The Six Sigma Belt System
Within Lean Six Sigma, a tiered hierarchy modeled after martial arts is used to denote the level of training and experience of an individual.
The Lean Six Sigma belt levels include:
- White Belts: Entry-level skill, with a basic understanding of LSS principles.
- Yellow Belts: Understand the fundamentals of LSS, including DMAIC methodology. At this level, they may participate as a team member in projects, but do not typically lead them.
- Green Belts: At this intermediate level, they may manage smaller improvement projects in their work area or work under a Black Belt in larger ones. They are proficient in data collection and root cause analysis, as well as use of basic statistical tools.
- Black Belt: They possess a deep understanding of lean and statistical analysis, along with an overall experience level that allows them to lead complex cross-departmental projects. Capable of training and mentoring White, Yellow, and Green Belts.
- Master Black Belt: The highest level of LSS expertise, they are capable of strategically deploying LSS across divisions and organization-wide. They often develop strategies and training materials and mentor Black Belts. They may also train, coach, or certify other belt levels.
While there is no fixed degree requirement for LSS consultants, they come from a variety of backgrounds including industrial engineering, quality assurance, supply chain management, and business process improvement and possess a natural ability to train, coach, and mentor.
Lean Six Sigma (LSS) Consultant Cost, Pricing, and Value
When hiring a LSS consultant to help improve your productivity, cost, and pricing are often the top concerns for management. This, however, is putting the cart in front of the horse so to say. As a leader you are looking for results, improving the right processes and in identifying these opportunities early on with one of our LSS consultants puts you in the driving seat for continuous improvement to be successful maximizing your investment.
Consider asking potential consultants these questions:
- How much downtime or waste can be reduced?
- What are the benefits to the business in terms of revenue, margin, cash flow, and employee productivity/satisfaction?
- What is the return on investment (ROI) on implementing LSS?
- What is the initial step to identify our business improvement opportunities?
- How do you plan improvements to be successful?
- What are the typical improvement activities or areas of improvement as the continuous improvement program matures?
You get what you pay for. If you choose, for example, low online training with an online test without a project or coaching to accelerate results you potentially get the lowest value for money. By asking the questions above it helps you understand the value the LSS consultant brings to help you and to make the right decision in driving the right rapid productivity.
Implementing LSS projects that deliver meaningful productivity, quality improvements, efficiency gains, and reduced rework, often pays for itself within months.
3 Qualities to Look for When Hiring a Lean Six Sigma Consultant
Not all LSS consultants will be a fit for your organization. Here are some things to look for that will help you make the right choice.
- Lean Six Sigma Consultant Experience in Your Industry: While Lean Six Sigma principles and techniques can be applied to manufacturers in virtually any sector, a proven LSS consultant’s experience in your industry is key to identifying quick wins. Examine the consultant’s track record of helping organizations with similar size, complexity, and regulatory environment as yours. Ask potential candidates for examples or case studies from previous clients in your industry that show measurable improvements in areas like scrap rates, cycle times, or increased throughput.
- Excellent Communication Skills: Lean Six Sigma relies heavily on soft skills to engage your team, data analysis and insight, and in putting that data to work to drive rapid results. The best LSS consultants are strong communicators who can express how the process benefits both the organization and team members individually. Strong, clear communication is essential to earning trust on the production floor and guiding teams successfully through understanding and improving the process. Ask each prospective consultant you speak with how they handle common challenges like resistance to change, or what methods they use to engage teams. The best LSS consultants aren’t just number crunchers—they are teachers and mentors to your team.
- Adaptable Approach: Even when a LSS consultant has worked with other organizations in the same industry as yours, they still must be able to adapt their approach to your organization. Choosing the best LSS consultant for you means finding someone who can tailor their strategy to your resources, culture, and overall goals. When choosing a LSS consultant, ask how they can adapt LSS methodologies to fit your company’s unique needs.
Common Mistakes When Choosing a Six Sigma Consultant
Avoid making these common mistakes when hiring a LSS consultant:
- Making cost the number one differentiator: If seeking the lowest LSS fees is your primary motivation, you can end up with a less experienced consultant whose skillset doesn’t match your company’s needs. This can ultimately cost you more in setbacks and lost opportunities than a higher-priced consultant would.
- Neglecting company fit: A consultant that doesn’t mesh with your company culture will have a harder time getting your staff to buy into a new way of doing things. Remember, the best LSS consultants are teachers and mentors, as well as data-driven professionals.
- Failing to define success: You need to be upfront with the consultant about your goals and expectations. Establish KPIs early on, so that both your organization and the consultant are on the same page about what constitutes success.
- Lacking long-term vision: Successfully implementing LSS isn’t a one-and-done install. Your chosen consultant must also train and mentor your staff, instilling a culture of continuous improvement in your workplace. Otherwise, you risk regression and may lose the value of your investment over time.
Key Questions to Ask Before You Hire a Lean Six Sigma (LSS) Consultant
Before you settle on any one particular LSS consultant, be sure to ask these fundamental questions:
- What quantifiable results have you achieved with similar clients?
The consultant should demonstrate a track record of prior success in your industry. Ask for concrete metrics, like defect reduction percentage, yield improvements, and process time savings. - How do you tailor your LSS approach to different industries?
It’s important that the LSS consultant you choose be able to adapt their approach to your specific industry. Avoid consultants that use a one-size-fits-all approach. - What certifications and credentials does the consultant hold?
A certified Green Belt LSS consultant, with project-based expertise may be able to implement methodologies at a smaller organization, but larger organizations often require the depth of knowledge and experience of a Black Belt or higher level/caliber. - Can you provide LSS training or certification for our internal staff?
A LSS Black Belt or Master Black Belt can train, coach, and certify members of your staff to create a sustainable continuous improvement program for your business. This is a key differentiator that can increase your team’s capabilities, and help your organization become self-sufficient in process improvement. - How do you sustain results?
Even well-implemented LSS and continuous improvement projects can lose steam over time if results are not monitored. Ask how the consultant ensures results are sustained over time, whether it’s through internal audits, control plans, or ongoing mentoring.
Manex: Skilled Lean Six Sigma Consultants for California Manufacturers
At Manex, our LSS consultant services help you and your team to see opportunities for continuous improvement and train, coach and drive rapid improvements to provide sustainable and improving business results.
We have a track record of delivering measurable and sustained results across industries ranging from aerospace and electronics to food and beverage production.
We do more than just teach LSS—we partner with your team to improve productivity, reduce waste, increase quality, and upskill your workforce with hands-on manufacturing knowledge.
Manex’s Lean consultant services will help you:
- Identify the ideal projects that will yield fast results.
- Establish metrics to monitor progress now and into the future.
- Create a culture of continuous improvement through coaching and documentation.
- Build, train, coach, and certify your internal LSS teams.
Whether you’re new to LSS or looking to increase the performance of existing initiatives, Manex has the skill and experience to guide your organization.
Contact Manex today for an initial consultation to discuss how our LSS consultants can bring measurable improvement to your organization.
