Lean Six Sigma is a method used in many large organizations to look for improvements in business efficiency and effectiveness. It relies on a team-based approach to focus on the customer, on removing waste, and on improving processes. The Postal Service and the Office of Inspector General are among the many companies and organizations that use Lean Six Sigma as a continuous improvement tool to try to get at the root of the problem rather than just solve the problems as they arise. Management uses the insights gained from the Lean Six Sigma approach to reduce variations in processes and systems.

Lean Six Sigma has loyal adherents in many industries, but some critics have argued that it is primarily effective only in product manufacturing. Others suggest that soliciting ongoing input from your employees is one of the most effective ways to improve processes and encourages their ownership in the process. Finally, some critics note that Lean Six Sigma only promotes incremental improvements, not radical breakthroughs.

The OIG has found Lean Six Sigma to be useful in automating processes, shortening process cycle time, reducing paper usage, and improving high-volume and high-usage databases. Eliminating waste and strengthening processes results in cost savings and improved efficiencies. The Postal Service has employed Lean Six Sigma and other continuous improvement efforts in several of its processes, including relocation, payables, receivables, and some claims processing. The Postmaster General recently stressed the importance of these tools to the Postal Service’s plan to accomplish the business changes necessary to compete in today’s marketplace. He touted the Value Stream Map (VSM) as a Lean Six Sigma tool that is being used effectively to look at all components of an end-to-end process.

We would like to hear your thoughts on Lean Six Sigma. If you have had it applied to your job, or to processes you use, did it drive down costs and improve service? Did it improve the overall customer experience? Are processes significantly better because of Lean Six Sigma? Or have you found there are better ways to improve processes and increase efficiency without using a Six Sigma approach? Are there better ways to achieve significant breakthroughs?

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  • anon

    The process is a joke. If truly a "team-based" approach, who is on the team? Apparently only managers at the district and area level, who have NO clue what the USPS does and how it works. As a rural carrier, they use these kind of processes to make my job more inefficient, in direct contradiction of our collective bargaining agreement. The NRLCA is a worthless union, that's why so few grievances under the "evaluated" system. I know the OIG is champing at the bit to get the NALC to join the evaluated system, but they are smart enough to see what happens when inefficiencies are forced upon non-hourly employees. The employees take the hit. When you enforce inefficiencies upon city carriers, although it bothers many of them, they don't take the financial hit. Six sigma, and the associated mgmt attitude, is what will cause the disintegration of the USPS. Packages won't save it.

    Oct 04, 2015
  • anon

    Hey Thanks for sharing this information.This is very nice thing to Learn the Lean Six Sigma.This is Important to improve the Efficiency ,effectiveness and Business Sustainability.

    Oct 04, 2013
  • anon

    <p><span>In my previous company (HVAC, Plumbing, Electrical) we used the Six Sigma process on many different projects. One of the most significant projects I was involved in was identifying an improved process of having parts returned for warranty reimbursement from the manufacturers. The new method had a tremendous impact on our bottom line and my bonus! I think it is a good method for breaking things down to identify where improvement lies.</span></p>

    May 21, 2013
  • anon

    Interesting.. I m glad to read your post

    Sep 16, 2014

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