Six sigma survivor here as well. Agree entirely.
I also agree, to an extent. I nearly quit my job for being forced to take the week long program and dealing with all the statistics and crap. However...
There is no process that is minimal, particularly those dealing with people. Some processes are institutionalized and can be a great opportunity for reducton. Especially when the money to implement the projects is essentially unlimited. Many process improvements are free.
Here's a process:
Employee wants to use a Medical Reserved parking space due to a recent injury. This is not a permanent requirement for which Handicap spaces are available.
Employee visits company nurse who agrees
Nurse writes a memo to Facilities to issue a pass.
Facilites reviews the request and writes a memo to Security to issue the pass.
Security issues the pass.
Here's the revised process:
Employee stops by Security and gets the pass. This works because all employees are adults.
There are literally hundreds of these processes where change actually improves the work environment, cost no money to implement and reduce costs although that may be hard to show. The work always got done, there is no headcount reduction so costs weren't really reduced. But if you find enough of these things, somebody will be out the door and costs will be reduced. That's the real goal of Six Sigma. It has little to do with quality and much to do with cost reduction.
I like these process improvement projects because they result in less work. They result in the removal of institutional bureaucracy and, when in my job function, allow me to get on with the work and avoid all the nonsense.
I'm still not a fan of statistics or the QC aspects of Six Sigma but I do like the way the program allows, even encourages, me to change processes. Mine or someone else's.
Want to get rid of somebody? Just start a Sig Sigma project to prove their work is redundant and unnecessary. Or show cost savings of just outsourcing their work. Remember, there are no retirement costs for outsourcing. This only applies to companies with defined benefits plans...
"Core Competency" can be used to remove entire departments. If a department doesn't relate directly to the product, outsource it. It wasn't a core competency.
That's kind of ruthless! Well, yes, but I would rather be the surviving 'idea guy' than one of the ones thrown under the bus.