Many of you may remember the Six Sigma craze of the late 1990s and early 2000s. And for those who came along later, here’s the quick version: A new theory takes off after being showcased in a respected company, evangelized by a charismatic leader, and packaged by consultants. Before long, leaders jump on the bandwagon for fear of missing out.
That’s exactly what happened with Six Sigma. Born at Motorola, later popularized at GE by Jack Welch, it trained more than a quarter-million “Black Belts” in its heyday. The method was powerful and delivered real results. But by 2010, the shine had worn off. Today, it’s estimated that fewer than 8,000 Black Belts are still practicing across industries.
So what happened? Leaders fell into the Frontline Change Trap—turning a method into doctrine. Instead of using tools to support employee wisdom, they forced every problem through rigid steps. Projects stretched for months. Frontline solutions were delayed while data was gathered and charts produced. Engagement plummeted. That’s when we heard the backlash: “Sick Sigma.” “Lean is Mean.”
One case stands out. A frontline scientist suggested a simple fix to a drug storage problem on day one. But the Black Belt assigned insisted on months of statistical experiments to prove it. The solution was right all along, but the delay cost millions—and patients.
The lesson isn’t that Six Sigma or Lean are dead. Far from it. The lesson is that methods are tools, not goals. The best practitioners know when to use advanced analysis and when to move quickly on frontline wisdom. That balance is what keeps methods relevant in the age of AI and disengagement.
In my book Ideas to Action, I explore how leaders can avoid the Frontline Change Trap and build cultures where employee ideas drive measurable results. Because the best consultants are already on your payroll.
Take the Next Step to Employee-Powered Innovation
This is Issue 5 of the Ideas-to-Action Video Newsletter with author Rick Tucci—a chapter-by-chapter journey into the mindset, method, and results of employee-powered innovation.
- Missed Issue 4? Watch it here.
- Want to dive deeper? Get the book on Amazon.
- Explore the full suite of Ideas-to-Action Solutions: www.ideastoactionplatform.com
