Common Lean Six Sigma Project Failures and How to Avoid Them

Lean Six Sigma (LSS) is a powerful methodology that can lead to significant improvements in quality, cost, and customer satisfaction. But despite its benefits, not every LSS project succeeds. Many fall short—not because the tools are flawed, but because of how they're applied.

In this post, we’ll uncover common Lean Six Sigma project failures, explain why they happen, and show you how to prevent them so your improvement efforts deliver real results.

1. Poor Project Selection

The Problem: Choosing projects that don’t align with business goals or lack measurable impact is a recipe for failure. Teams may also pick projects that are too broad, too complex, or not ready for Six Sigma rigor.

Why It Fails:

• Low ROI

• Lack of executive interest

• Difficulty defining success

How to Avoid It:✅ Use criteria like impact, effort, alignment to KPIs, and data availability✅ Start with “low-hanging fruit” to build momentum✅ Use a project selection matrix to prioritize wisely

2. Vague Problem Statements

The Problem: When the problem is unclear, the project flounders. A poorly defined issue leads to unfocused analysis and ineffective solutions.

Why It Fails:

• Scope creep

• Misaligned team efforts

• Confused stakeholders

How to Avoid It:✅ Use SMART (Specific, Measurable, Achievable, Relevant, Time-bound) criteria✅ Clearly define the problem, goal, and baseline at the Define phase✅ Validate with data early on

3. Lack of Leadership Support

The Problem: Leadership doesn’t actively sponsor or follow up on the project. Without visible backing, teams lose direction and motivation.

Why It Fails:

• Resource roadblocks

• Delayed decision-making

• Resistance to change

How to Avoid It:✅ Engage sponsors from Day 1✅ Provide regular updates and involve them in key tollgates✅ Communicate business impact clearly

4. Inadequate Data or Poor Data Quality

The Problem: Many projects fail when they rely on anecdotal evidence or poor-quality data. Inaccurate data leads to faulty analysis and bad decisions.

Why It Fails:

• Flawed root cause analysis

• Inappropriate solutions

• Misleading metrics

How to Avoid It:✅ Conduct a Data Quality Assessment early✅ Use operational definitions✅ Automate or systematize data collection when possible

5. Jumping to Solutions Too Early

The Problem: Teams often rush to fix things before properly understanding the root cause—bypassing the Measure and Analyze phases.

Why It Fails:

• Superficial fixes

• Recurring problems

• Waste of resources

How to Avoid It:✅ Stick to the DMAIC structure✅ Use tools like Fishbone, 5 Whys, and Pareto Charts to explore causes✅ Test assumptions with data before acting

6. Lack of Change Management

The Problem: Even when the solution is right, failure to manage change leads to poor adoption.

Why It Fails:

• Frontline resistance

• Confusion about new processes

• Reversion to old habits

How to Avoid It:✅ Involve stakeholders early and often✅ Use tools like RACI, communication plans, and training✅ Highlight quick wins to build buy-in

7. No Sustainability Plan

The Problem: After implementation, there’s no follow-up. Processes slowly revert to their old ways, and the gains are lost.

Why It Fails:

• No monitoring

• No accountability

• Lack of process ownership

How to Avoid It:✅ Build Control Plans with metrics, responsibilities, and reaction plans✅ Implement visual management (e.g., dashboards, control charts)✅ Assign clear process owners post-project

8. Overcomplicating the Approach

The Problem: Using complex tools when simpler methods would suffice, or trying to do too much in one project.

Why It Fails:

• Team confusion

• Extended timelines

• Analysis paralysis

How to Avoid It:✅ Tailor the tools to the problem✅ Use the "Just Enough" principle—right tool, right time✅ Train teams in both Lean and Six Sigma fundamentals

✅ Conclusion: Set Up for Success

Failure in Lean Six Sigma isn’t inevitable—it’s avoidable. With the right project selection, strong leadership, disciplined methodology, and a solid plan for change, your team can avoid the pitfalls and make your improvement efforts stick.

🧭 Remember:

“A successful project isn't just about solving a problem—it's about sustaining the solution.”

📌 BONUS: Lean Six Sigma Success Checklist

✔ Clear project charter✔ Executive sponsor identified✔ Reliable baseline data✔ Root cause validated✔ Stakeholders engaged✔ Control plan in place✔ Results tracked over time