Process Improvement

Process Improvement & Optimization with Lean Six Sigma

We reduce lead times, errors, rework and cost in real processes, using the right method for each problem and measurable targets from the start.

  • DMAIC
  • Kaizen
  • Process redesign

What is process improvement?

Process improvement is the systematic analysis and change of how work is done, so that it delivers the right result faster, with fewer errors and fewer resources.

Process optimization is the next step: tuning a stable process to its best possible performance, backed by data.

First we stabilise, then we simplify, and only then do we automate. Automating a wasteful process simply produces waste faster.

Signs that a process needs improvement

  • Long or unpredictable lead times
  • Errors, complaints and rework
  • High cost per unit or per transaction
  • Bottlenecks at specific points
  • Large variation by shift or person
  • Overtime to keep up with demand

The right method for each problem

Just do it

Known cause, obvious fix. We implement, standardise and move on.

Kaizen workshop

A focused team, 2 to 5 days, improving one area or flow on the spot.

A3 / 8D

Structured problem solving for problems with an unknown cause, in a few weeks.

DMAIC project

Complex problems with variation, data analysis and statistical evidence.

Process redesign

When the process needs to be designed from scratch, often before digitalisation.

Digital & AI

Automation and AI built on a process that is already stable and simple.

See also Structured Problem Solving: A3, 8D & PDCA and AI for Operational Excellence.

How we run a DMAIC project

  1. DefineProject charter, customer and CTQs, scope, target and team. SIPOC map.
  2. MeasureProcess mapping, data collection plan, measurement system analysis (MSA) and baseline.
  3. AnalyzePareto, cause and effect diagram, 5 Whys, hypothesis tests and confirmation of root causes.
  4. ImproveSolution selection, FMEA, pilot test and measurement of the result.
  5. ControlControl plan, standard work, SPC and handover to the process owner.

What we measure

  • Lead time
  • Cycle time
  • Waiting time
  • Defect rate
  • First Pass Yield
  • Rework
  • OEE
  • Productivity
  • Cost per unit
  • Customer satisfaction

We define the KPI and the baseline before the change starts, so the result is measurable rather than an impression.

Ways to work with us

Coached project

Your team delivers the project, we guide every phase.

Project coaching →

GLSS-led project

We lead the project with the participation of your people.

Training + project

Green Belt or Yellow Belt with a real organisational project.

Lean Six Sigma Belts →

Kaizen workshop

One week of focused improvement in one area.

Process improvement: frequently asked questions

What is the difference between process improvement and process optimization?

Improvement changes how work is done to remove waste and errors. Optimization tunes an already stable process to its best performance level, based on data.

How long does an improvement project take?

A Kaizen workshop takes a few days, an A3 a few weeks and a DMAIC project usually 3 to 6 months, depending on complexity.

Do we need data to start?

Not necessarily. In the Measure phase we design together how to collect the right data, often with simple means.

Does it apply to services and back office?

Yes. Every process with inputs, steps and an output can be improved: reservations, invoicing, purchasing, customer service, HR.

Should we digitalise first?

Usually not. We first simplify and stabilise the process. That way digitalisation or AI delivers more and costs less.

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Confidential by design

We never publish client names, logos, photographs or data. What we learn in your organisation stays there.

Which process do you want to improve?

Describe the problem and we will recommend the right method. We work with organisations in Greece, Cyprus and across Europe, on site and online. Telephone: +30 231 231 5681, email: info@greeceleansixsigma.gr

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