What purpose, if any, does Six Sigma serve in economic downturns? Full disclosure: I teach and consult in Six Sigma and related areas, and you’re reading this article because you’re interested in Six Sigma, so we may not be the most objective people to assess this, but in this article, I will do my best to find the truth.

I remember when I was working as an engineer for a company that made aluminum for aerospace and commercial applications. One of the apparently inevitable downturns in aerospace was occurring and the company was looking to cut costs, critically eyeing headcounts. At the same time, there was a consulting team training and implementing the technology that would one day be called Six Sigma.

Of course the talk around the table in the lab revolved around the uncertainty of the times, and sooner or later someone would begin to complain that the company was spending enough money on consultants each year to avoid laying off four full-time employees. I was torn in what I thought. On the one hand I was a recent hire, and thus first in line for the chopping block, but on the other, I also knew that the benefits the company and employees were accruing from what the consultants had to teach us was enormous.

 …