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Insights for Operational Excellence

Read the latest articles on Lean Six Sigma, process improvement, and achieving operational excellence. Get real-world strategies and tools you can apply today.

Featured Blog

What Is Optical Metrology

What Is Optical Metrology? Techniques, Applications, and Six Sigma Role

Measurement is the foundation of quality control. You cannot improve what you cannot measure — and you cannot measure reliably without the right instrument. For many precision manufacturing environments, contact gauges have real limitations. They can deform soft...
Can Startups Benefit From Lean Six Sigma

Can Startups Benefit From Lean Six Sigma? A Practical Answer

Startups benefit from Lean Six Sigma, but only in small, targeted doses. The value comes from protecting cash and building good habits early. A full corporate-style rollout is the wrong move for most early teams. This is a resource question before it is a methodology...
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How Xerox Built a Company-Wide Lean Six Sigma Program

Xerox Corporation is one of the most recognized names in business technology. It invented the photocopier. It pioneered the laser printer. It transformed how offices manage documents worldwide. And in the 2000s, it made a commitment that would reshape how it works...
Do Employers Value Lean Six Sigma Certifications

Do Employers Value Lean Six Sigma Certifications? The Data Answers the Question.

Yes. Employers actively list Lean Six Sigma certification as a job requirement across industries. Job postings requiring LSS skills grew 33% between 2020 and 2024. Over 48,000 US vacancies referenced Six Sigma on any given day in 2025. Certified professionals earn an...
Biggest Mistakes Beginners Make in Lean Six Sigma

Biggest Mistakes Beginners Make in Lean Six Sigma (And How to Avoid Them)

Every new Lean Six Sigma practitioner makes mistakes. That is expected. The methodology is rigorous, the statistical tools are demanding, and the organizational dynamics are complex. But most beginner mistakes are not random. They follow a predictable pattern. The...
What Is Scrum of Scrums

What Is Scrum of Scrums? Definition, Meeting Format, and Six Sigma Connection

When a product grows too large for one Scrum team, organizations split the work across multiple teams. That split solves a capacity problem. But it immediately creates a coordination problem. How do five or eight or twelve Scrum teams working on the same product stay...
Most Common Lean Six Sigma Interview Questions

Most Common Lean Six Sigma Interview Questions (With Answers)

Employers who hire for process improvement roles test candidates on three things. They test technical knowledge of Six Sigma tools. They test practical experience applying DMAIC. And they test how candidates think when facing a real process problem. This article...
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How Ford Motor Company Uses Six Sigma and the Ford Production System

Ford Motor Company has built and sold vehicles for more than 120 years. It employs approximately 177,000 people across the globe. It operates manufacturing plants, assembly facilities, and engineering centers across multiple continents. At that scale, quality is not...
How Difficult Is the Lean Six Sigma Exam

How Difficult Is the Lean Six Sigma Exam? What the Facts Show by Belt Level

The Lean Six Sigma exam ranges from moderately to significantly challenging, depending on belt level and certifying body. The IASSC Black Belt is a 150-question, closed-book, proctored exam with a 70% minimum passing score. The ASQ Black Belt contains 150 to 165...
What is Micromachining

Micromachining: What It Is, How It Works, and Why Quality Control Matters

Modern devices keep shrinking. Smartphones, cardiac stents, satellite sensors, and automotive airbag triggers all share one common thread. They all contain components measured in micrometers. Micromachining produces those components. It creates features and parts at a...

Why read this blog?

This blog is your go-to resource for Lean Six Sigma and process excellence. It cuts the fluff. It will give you clear, actionable advice on core tools like DMAIC, Kaizen, and Value Stream Mapping. Use these insights to solve real-world problems and drive measurable results in your business.

We publish practical strategies for practitioners at every belt level. You will find relevant content whether you are a Green Belt or a Black Belt.

Start reading today. Transform your processes and achieve lasting operational excellence.

Latest Posts

How Xerox Built a Company-Wide Lean Six Sigma Program

How Xerox Built a Company-Wide Lean Six Sigma Program

Xerox Corporation is one of the most recognized names in business technology. It invented the photocopier. It pioneered the laser printer. It transformed how offices manage documents worldwide. And in the 2000s, it made a commitment that would reshape how it works...

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Meet The Author

Headshot of Kevin Clay for Why They Fail Podcast

Kevin Clay, MBB

Kevin is a Lean Six Sigma Master Black Belt and President of Six Sigma Development Solutions, Inc. Moreover, Kevin has spent over 25 years in the trenches of process improvement and Six Sigma implementation. He’s seen everything from amazing successes to total disasters. As a Master Black Belt and executive consultant, he’s helped companies across all industries transform how they work.

What makes Kevin different isn’t his impressive resume. It’s his core belief that our biggest failures teach us the most valuable lessons. Through authentic conversations and real stories, he creates a space where professionals can learn from others’ mistakes without having to make them all themselves.

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