Six Sigma and Lean are complementary approaches to reducing cost, waste and variation: Lean strips out non-value-adding activity through tools like 5S and value stream mapping, while Six Sigma's DMAIC framework (Define, Measure, Analyse, Improve, Control) uses data and statistical process control to find and permanently fix the causes of variation and defects.
This service is led by a Six Sigma Master Black Belt — the highest level of Six Sigma qualification, focused on leading complex projects and coaching Black Belts and Green Belts — applied to real automotive and manufacturing environments, not a classroom exercise.
You know cost, waste or variation is a problem but need a structured, data-led way to fix it.
You want your own people trained and capable of running improvement projects, not permanently dependent on consultants.
Structured, data-led improvement projects scoped around your highest-cost problems.
Workplace organisation and waste elimination that sticks, not a one-off tidy-up.
Control charts and capability studies (Cp/Cpk, Pp/Ppk) that show whether a process can actually meet specification.
Mapping the current and future state of a process to identify where waste and delay really sit.
Green Belt and Yellow Belt training via our training programme, with live coaching on real projects.
Focused, time-boxed improvement events targeting a specific process or problem.
We scope the problem, agree the business case and baseline current performance with real data.
We identify the root causes of variation, waste or defects using statistical and Lean tools.
We design, trial and implement improvements targeted at the confirmed root causes.
We put controls in place — SPC, standard work, training — so the improvement sticks after we leave.
It's the highest level of Six Sigma qualification, awarded to practitioners with extensive experience leading complex improvement projects and training and mentoring Black Belts and Green Belts across an organisation.
No — Six Sigma and Lean can be applied to any process, certified or not. That said, if you do hold ISO 9001 or IATF 16949, improvement projects and SPC data can feed directly into your existing management system.
The core tools (APQP, PPAP, FMEA, MSA, SPC) are specific to automotive product launch and control. Six Sigma and Lean are broader improvement methodologies that can be applied to any process, in or out of automotive — though SPC is shared between the two.
A focused DMAIC project usually runs 8 to 16 weeks depending on complexity and data availability; a Kaizen event can be as short as a few days.
We quote a fixed price per project or a retainer for ongoing improvement support, agreed after a free scoping call based on the scale of savings targeted.
Most of our clients need more than one of these — here's what tends to go together.
APQP, PPAP, FMEA, MSA and SPC implemented and coached until your team owns them.
Structured root cause analysis that closes issues out for good — 8D, 5-Why, CAPA.
Quality management certification, gap analysis and 2026 transition support.
Your part-time, outsourced QHSE manager — keeping the system live between full-time hires.
Tell us about the process or problem and we'll scope a project with a clear business case.
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