Introduction: What is Problem Solving with Lean Six Sigma?
Problem solving with Lean Six Sigma is a structured, data-driven approach to improving business performance by eliminating root causes of defects and reducing process variation. It goes far beyond guesswork or quick fixes by applying the DMAIC methodology—Define, Measure, Analyze, Improve, Control.
From manufacturing lines to pizza delivery services like Jv’s Pizza, Lean Six Sigma problem solving equips teams with a repeatable system to identify issues, make informed decisions, and implement long-lasting improvements.
In this article, you’ll learn how Lean Six Sigma transforms reactive problem solving into a culture of continuous improvement.
Why Traditional Problem Solving Falls Short
Most traditional problem solving is reactive:
- “Let’s add more people.”
- “Let’s do it faster.”
- “Let’s fix it for now.”
These temporary actions rarely address root causes. They often solve the symptom, not the system—and issues resurface again and again.
Lean Six Sigma problem solving changes this by using structured problem-solving steps backed by data and focused on sustainable outcomes.
What Makes Lean Six Sigma Problem Solving Unique?
What distinguishes Lean Six Sigma problem solving is its rigor and structure:
- Structured – It follows the DMAIC methodology
- Analytical – Relies on quantitative data, not opinions
- Root cause-driven – Eliminates causes, not just symptoms
- Customer-focused – Solves what impacts the end-user most
- Sustainable – Uses control mechanisms to keep gains in place
It’s a problem-solving system that works in every industry and at any scale.
Step-by-Step: The DMAIC Framework for Problem Solving
The DMAIC framework is at the heart of Lean Six Sigma problem solving:
1. Define – Frame the Problem
Identify what’s wrong and why it matters from the customer’s point of view.
Example (Jv’s Pizza):
Customer satisfaction is falling due to long delivery times. The team defines the problem as:
“Reduce average delivery time from 47 minutes to under 30 minutes within 60 days.”
2. Measure – Gather and Validate the Data
Measure how the process is currently performing using relevant metrics.
Jv’s Pizza collects:
- Time for order entry
- Kitchen prep time
- Post-bake wait time before dispatch
- Delivery time
Baseline: Total average = 47 minutes
3. Analyze – Identify Root Causes
Use data to uncover the real reasons behind the problem.
At Jv’s Pizza, analysis shows:
- Orders wait 10+ minutes after baking due to inefficient dispatch
- Manual batching of deliveries causes delays
- Drivers lack real-time routing info
4. Improve – Fix the Process
Brainstorm and test solutions to address root causes directly.
Improvements implemented at Jv’s Pizza:
- Live dashboard for order readiness
- Digital dispatching system
- Elimination of manual batching
- Updated SOPs for kitchen and drivers
Result: Delivery time drops to 28 minutes.
5. Control – Sustain the Results
Monitor the improved process and ensure gains don’t fade over time.
Control measures at Jv’s Pizza:
- Weekly delivery time tracking
- SOP adherence checks
- Real-time metrics board in the kitchen
Benefits of Problem Solving with Lean Six Sigma
Applying Lean Six Sigma to solve business problems delivers:
- Fewer recurring issues – Root causes are eliminated
- Improved customer satisfaction – Faster, more reliable service
- Lower costs – Reduced waste and rework
- Better team engagement – Everyone becomes a problem solver
- Data-driven decision making – Less guesswork, more precision
- Sustainable outcomes – Problems stay fixed, not patched
When to Use Lean Six Sigma Problem Solving
Use Lean Six Sigma problem solving when:
- The problem occurs repeatedly
- The root cause is unclear
- The process is measurable and stable
- You need sustainable, not temporary solutions
- Cross-functional collaboration is required
- There’s support to follow a structured method like DMAIC
Problem Solving in Action: Jv’s Pizza Summary
| Phase | What They Did |
|---|---|
| Define | Set goal to reduce delivery time |
| Measure | Collected timing data on each process step |
| Analyze | Identified batching and dispatch issues |
| Improve | Installed real-time routing and stopped batching |
| Control | Monitored delivery time and maintained standards |
Result:
Delivery time dropped by 40%
Customer complaints fell by 70%
Repeat orders increased
Final Thoughts: Smarter Problem Solving Starts Here
Problem solving with Lean Six Sigma is more than a methodology—it’s a mindset. It enables organizations to go beyond surface-level fixes and deliver sustainable, data-backed solutions that improve performance over the long term.
Whether you run a factory, a financial firm, or a pizza delivery business, Lean Six Sigma gives you the structure, focus, and tools to solve problems for good.
Want to master Lean Six Sigma problem solving?
Explore step-by-step training, DMAIC templates, and certification options at Lean 6 Sigma Hub and start solving smarter today.
