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      How we can help

      Lean Six Sigma

      By combining lean manufacturing with digital capabilities companies can eliminate more waste, save more money and efficiently execute their manufacturing strategies. We provide the expertise and tools you need to accelerate your progress and transform your business.

      Lean Six Sigma
      • Overview
      • Qué esperar
      • Our Impact
      • Our Team
      • Our Insights
      • Related Offerings

      Lean Six Sigma integrates traditional lean methodologies with a robust set of digital capabilities to transform your manufacturing operations. We focus on the areas of greatest value—for example, using overall equipment effectiveness (OEE) to identify high-potential opportunities. We deploy lean tools selectively, applying the right ones based on current strategy, the value at stake and the front line’s ability to adopt them.

      We help you enforce line accountability, ensuring that change is led by frontline management and embedded in the daily steering routine. And we help you get results fast, using a three-phase approach (diagnose, design, implement) that quickly advances you to your future state. Our Manufacturing Full-Potential Diagnostic assesses your starting point across four critical areas of manufacturing (Lean, digital/Industry 4.0, supply chain and footprint design) supported by a robust set of proprietary benchmarking data. Our approach to digital also includes Four-Wall Lean Full-Potential, a complementary capability that ensures you reduce complexity and enhance productivity.

      For a closer look, our Digital Lean Playbook explains how we help you apply the right technologies across seven distinct levers to transform your operations and become a performance leader.

      Read more Read less

      Qué esperar

      Qué esperar

      Capability

      Our tools, training and change management expertise ensure that your teams have the data and skills they need to extract maximum benefits from digital lean

      Digital mastery

      Apply the right technologies to every facet of factory performance, from the shop floor to health & safety, TQM, planning, support, and more

      Accountability

      Leverage a Results Delivery® office to centrally track all digital lean projects, reprioritizing as needed as you continually monitor progress

      Impact

      Combing digital and Lean can reduce costs by up to 30%, compared to just 15% for traditional Lean efforts

      Our Impact in Lean Six Sigma

      Our Impact in Lean Six Sigma

      -30%

      Potential cost reduction when combining digital and lean, compared to -15% using only traditional lean

      +35%

      Typical boost to overall equipment effectiveness (OEE)

      -20%

      Decrease in production time when adopting a digital lean approach

      Our Client Results

      Case study

      Streamlining engine assembly boosts output
      AutoCo charged Bain with improving productivity on the main assembly line to produce five more engines per hour. Our recommendations doubled the client's original cycle time reduction goal.

      Case study

      Lean Six Sigma improves plant performance and cuts costs
      Bain incorporated Lean Six Sigma principles to improve FoodCo’s plant performance, which yielded 15 percent cost savings and increased flexibility.
      see more

      Our Lean Consulting Experts

      Headshot of Pierluigi Serlenga

      Pierluigi Serlenga Partner Rome

      Headshot of Frank Lesmeister

      Frank Lesmeister Partner Dusseldorf

      Headshot of Ilkka Leppävuori

      Ilkka Leppävuori Partner Helsinki

      Headshot of Marzio Forlini

      Marzio Forlini Partner Milan

      See More

      Our Insights on Lean Six Sigma

      Digital Tools Can Double Lean Six Sigma Savings
      New technologies are reinventing a tried-and-true approach to operational excellence.
      Operations Excellence
      When Lean Manufacturing Loses Steam
      Too many bottom-up changes with no steer from the top can derail the effort to improve efficiency.
      Operations Excellence
      Total Quality Management
      Bain's Management Tools & Trends survey focuses on the 25 most popular tools and techniques that are relevant to senior management, topical (as evidenced by coverage in the business press) and measurable.
      Management Tools
      Harnessing Digital in Manufacturing
      Many digital efforts aren’t tied to a broader strategy. Go beyond experimentation to deliver lasting returns.
      Infographic
      See more

      Related Offerings

      Operations

      Operations

      How much better, faster or smarter could you do what you do? 

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      Manufacturing

      Manufacturing

      Master digital operations and processes to become an Industry 4.0 leader 

      Read more

      Procurement

      Procurement

      We help companies develop sourcing strategies for a sustainable future.

      Read more

      Service Operations

      Service Operations

      Balance quality, cost and revenue objectives as you delight customers and motivate employees

      Read more
      See more

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