Six Sigma and Design Thinking for Massive Growth

Even though I studied the world’s most popular business methodology for

quality and process improvement decades ago, Six Sigma remains a trusted

tool for myself and business managers aiming to eliminate errors,

streamline processes and drive measurable results.

I’m glad I completed the work to earn my Black Belt because as a leader of

business operations I have continually used this methodology to insure

efficiency while minimizing risk. It has become one of my favorite tools, and

I never go into a business without it.

But there’s an old saying that past success is the enemy of future progress. Getting too comfortable, even with a tool as powerful as Six Sigma, can blind you to what’s even better.

Recently, our client embarked on a Six Sigma consulting journey, achieving significant improvements that reflect the lasting power of this approach. But the reason it worked so well was that Six Sigma wasn’t working alone. It had some help from another methodology: Design Thinking.

I want to tell you about that, but first, let’s take a look at where Six Sigma started, how it has transformed industries, and why it remains a go-to solution today.

A Brief History of Six Sigma

Six Sigma was born in the mid-1980s at Motorola, where it was developed as a strategy to eliminate defects in manufacturing.

The initiative was led by Motorola engineer Bill Smith, who aimed to create a system that reduced process variability and increased product reliability. It quickly proved its value, helping Motorola save an astonishing $17 billion over the first decade.

In the 1990s, Six Sigma took a quantum leap forward when General Electric (GE), under CEO Jack Welch, adopted and evangelized the program.

Welch pushed Six Sigma beyond manufacturing, demonstrating its effectiveness in all aspects of business, from operations to customer service.

By the end of the decade, GE reported savings of $12 billion, catapulting Six Sigma into the spotlight as a universal approach for business improvement.

Why Six Sigma Works: Tangible Success Across Industries

Six Sigma is rooted in a structured framework called DMAIC—Define, Measure, Analyze, Improve, and Control—which systematically addresses problems to reduce errors and enhance efficiency.

Over the years, it has delivered billions in savings across industries such as:

Manufacturing: Companies like Motorola, GE, and Toyota have relied on Six Sigma to reduce defects and production waste.

Healthcare: Hospitals have used Six Sigma to improve patient outcomes by reducing errors, improving processes, and enhancing care quality.

Finance & Services: Financial institutions have leveraged Six Sigma to eliminate delays, reduce transaction errors, and boost customer satisfaction.

Whether it’s saving billions or improving service quality, the results speak for themselves: Six Sigma delivers measurable and consistent value.

Six Sigma in Today’s Business World

While originally rooted in manufacturing, Six Sigma has evolved to meet the needs of modern business processes.

The rise of Lean Six Sigma, which combines Lean’s focus on eliminating waste with Six Sigma’s precision in reducing errors, has made the methodology even more versatile.

Today, it’s widely used in industries ranging from logistics and IT to healthcare and financial services.

For many businesses, Six Sigma is also a key part of digital transformation initiatives. By pairing Six Sigma’s data-driven insights with modern technologies, companies are achieving unprecedented levels of efficiency and innovation.

But you can take it even further by combining it with other methodologies like Design Thinking.

Our Client’s Six Sigma Success Story

When our client engaged us to optimize their processes, they knew they needed a proven solution to eliminate inefficiencies and achieve consistent, high-quality outcomes.

By implementing Six Sigma principles, they:

●      Reduced process errors by identifying and addressing variability.

●      Streamlined workflows, saving time and resources.

●      Enhanced customer satisfaction with more reliable and predictable results.

●      Minimizing future risk through implementation of control measures

The project not only delivered measurable improvements but also positioned our client to thrive in an increasingly competitive landscape.

Six Sigma remains an essential tool for businesses that want to drive innovation, reduce costs, and achieve excellence. In my next post, I’ll tell you about Design Thinking and what it brings to the DMAIC framework that really delivers results.

If you don’t want to wait, reach out to me. I’ll tell you the whole story. Then, we can discuss your goals to improve processes, eliminate waste, and achieve measurable results in your business. Six Sigma consulting may be the solution you need.

Michael Harris is Managing Director and Partner at BlackFin Group. Michael has over 20 years’ senior executive management experience in default servicing and mortgage servicing. He and his team are subject matter in all aspects of servicing strategy, investor relations, process, compliance requirements. Prior to BlackFin, Michael was the President & CEO of Jennick Asset Management and was responsible for developing the pilot outsourced management program for Fannie Mae, Freddie Mac, and HUD while working with the top 10 mortgage servicing and capital markets firms. For more information contact info@blackfin-group.com