Lean Six Sigma ROI & Certification: Is It Worth It?

Lean Six Sigma ROI & Certification: Is It Worth It? ROI Examples from Australian Businesses

Operational efficiency is critical for many Australian businesses navigating a competitive and uncertain landscape. From supply chain pressures to quicker turnaround times, the ability to continuously improve processes and outcomes can mean the difference between surviving and making profits. — particularly through Lean Six Sigma business outcomes

Lean Six Sigma is a training and development certification that allows businesses to understand their processes and implement structured improvements. However, it does take up valuable time, effort, and budget from employees and companies.

So, is Lean Six Sigma training worth it?

At OE Partners, we’ve seen firsthand how lean training delivers tangible returns for both individuals and their organisations. In this article, we’ll discuss the real-world project outcomes that the certification delivers and provide insights that prove the positive ROI of Lean Six Sigma training.

What Makes Lean Six Sigma ROI & Certification “Worth It”?

Let’s first explore what “worth it” really means. Evaluating the necessity of any training program comes down to the individual. But if you’re considering Lean Six Sigma as your path forward, here are some things to consider:

Career Benefits

For professionals, Lean Six Sigma certification can open doors to more senior roles, bigger projects, and higher salaries. The skills you gain, such as data-driven problem solving and the ability to lead large improvement projects, are in high demand in any industry.

Financial Impact on Projects

Businesses often want immediate and tangible ROI, which can be delivered by Lean Six Sigma training. Completed Lean Six Sigma projects usually save tens of thousands of dollars within months. Employers can also see benefits in waste reduction, customer satisfaction, and improved productivity.

Culture Change and Long-Term Impact

Beyond the financial and skills benefits, Lean Six Sigma creates a culture of continuous improvement within the organisation. Staff feel more engaged and empowered to solve problems, while companies get a proven framework that transforms their processes in the long term.

Professional Career Growth

These days, employees want to grow their careers within a company, and Lean Six Sigma training and certification helps achieve this. According to Australian job data reports, Lean Six Sigma skills are increasingly sought after. Here are some of the role progressions that we typically see for Green and Black Belt roles:

Green Belt-level roles: Business Improvement Lead, Operations Manager, Project Manager, Quality Manager, Supply Chain Manager.
Black Belt-level roles: Continuous Improvement Manager, Head of Quality, Operational Excellence Manager, Business Transformation Manager, and even COO or VP-level roles.

Quantifying the ROI: What Can You Expect to Gain?

Lean Six Sigma employees are presented with amazing career opportunities. Recent job market studies show that at any one time, more than 10,000 jobs related to operational excellence are listed in Australia alone.

Additionally, Lean Six Sigma certification has a proven track record in increasing one’s pay scale. Here is the expected salary one can expect with Green and Black Belt certification:

Green Belt Certification: Certified Green Belts worldwide report an average salary increase of +8.7%.
Black Belt Certification: Black Belts see even greater salary increases, making +10.5% on average.
Project Savings: Project savings for Green Belts typically exceed $30,000 per project, while Black Belts see more than $75,000 in project savings. Companies that adopt these projects into their processes typically result in 3 to 5 times increase in ROI for the first year alone.

As Lean Six Sigma trainers in Australia, we’ve seen firsthand the benefits it brings to professional employees and their companies. Here are some of the feedback from our previous clients:

“A new leadership team was created within DTS to drive change in the business. I saw the Lean Six Sigma training as an opportunity to build on my skill set and learn new ways to identify opportunities for process improvement.

This training has taught me the importance of putting in the time to collect, analyse and measure all data in order to make an informed decision. This then sets the project up for success.

The training was very good, and I’d recommend OE Partners and Lean Six Sigma Green Belt training to others.”
— Julie Stewart, DTS Food Labs, Technical Specialist - Processes

“Our organisation had a tendency for rework, which created operational inefficiencies. I wanted to learn Lean skills, be able to make a deep diagnosis of a problem and propose tangible improvements.

I now approach problems from multiple perspectives with a different, more open mindset. I’ve identified new areas of opportunity and have definitely seen operational improvements. I have already recommended OE Partners for their delivery of Lean Six Sigma training as I found the delivery terrific with the right combination of participation and theory.”
— Imtiyaz Rather, Baycorp, Project Officer

Case Study Highlights: Australian Businesses Driving ROI with OE Partners

Lean Six Sigma certification is more than just training. It produces tangible results in all business sectors. Here’s a closer look at real-world outcomes achieved through Lean Six Sigma training and project implementation with OE Partners:

Bob Stewart Retail

Challenge: Bob Stewart is an iconic Australian retailer with a decades-long legacy. As their operations scaled, they had to move to a larger warehouse. This process required a fresh look at operations to support growth.

Approach: OE Partners identified three priority areas: warehouse operations and layout, embroidery process improvement, and supply and demand planning.

Results:

We developed an operational assessment and ‘quick win’ plan in 2 weeks
Completed a new warehouse design in 4 weeks
Full implementation of new equipment and systems within 2 months
Bob Stewart gained greater efficiency, faster turnaround, and removed redundant roles through process improvements
The company saved over $100,000 annually

Incsub (Software & Tech)

Challenge: Incsub is a local company in the software and digital services space. They experienced rapid growth, leading to operational inefficiencies, lost clients, and confusion in task execution.

Approach: OE Partners focused on their WPMU DEV business unit, assessing how tasks were assigned, tracked, and completed. We worked alongside their teams to identify root causes of delays and errors to build solid, scalable solutions.

Results:

The company experienced a 96% reduction in unresolved bugs, reducing backlogs from 878 to just 29
Incsub experienced a 58% reduction in member cancellations within 3 months
OE Partners set up clearer task assignment and ownership frameworks, meaning staff knew exactly what they were responsible for

Regent Caravans

Challenge: The company needed to relocate to a 10,000 sqm factory, which required a Lean layout to support their remarkable growth.

Approach: OE Partners used Value Stream Mapping and Value Stream Design principles to improve their floor processes. We worked closely with the Regent Caravans team to map every step of their manufacturing and warehousing and identify areas of non-value-adding work.

Results:

The company adopted a simplified warehouse system for two production lines
Staff were happier and more engaged
Created a simpler, more visual system for managing warehouse stock and production inputs
The company projected a 10–15% increase in production efficiency with existing staffing

Rail Depot Transformation

Challenge: A major Australian rail operator struggled with reactive work practices and a blame culture. The company operated with a reactive firefighting approach with hidden data and misaligned expectations.

Approach: OE Partners partnered with site leaders and frontline staff to implement visual performance management, standardised data reviews, and build accountability frameworks.

Results:

61% reduction in work backlog
18% improvement in train arrival performance
Enhanced service fulfilment and staff ownership of improvement

Green vs Black Belt ROI: Which Delivers More Value?

If you’re considering between Green and Black belt, here’s a quick comparison to help you decide:

Belt Level	Typical Cost	Expected ROI	Payback Time
Green Belt	~$3,700	$30,000+	1–3 months
Black Belt	~$11,550	$75,000+	3–6 months

While both deliver strong returns, Black Belts typically bring larger strategic benefits to the company, while Green Belts focus on daily department-level improvements. Black Belts also typically hold leadership and transformation roles.

If you’re unsure which belt suits your organisation, our trainers are happy to guide you. Speak to our team to learn more about our programs.

Beyond Cost Savings: The Strategic Value of Certification

Beyond the financial and upskilling benefits, Lean Six Sigma’s impact is long-term for both the company and the employee. Here are some of the lesser-known benefits:

Culture of Continuous Improvement: Staff at every level know how to identify waste and optimise processes, which makes innovation part of the daily routine.
Higher Employee Engagement: Staff who are involved in real-world improvement projects have better morale and a sense of meaningful work every day.
Improved Customer Satisfaction: Better processes mean fewer errors in the long run. This results in happier clients and faster services.
Long-Term Capability Building: Certified team members become advocates of operational excellence within the company, resulting in a culture that’s adaptable and agile.

Who Should Invest in Lean Six Sigma? (And Who Shouldn’t?)

The ideal candidates for Lean Six Sigma depend on the belt level. Yellow Belts are typically frontline workers and team members who want to understand process improvement foundations and make meaningful contributions in their company.

Meanwhile, Green Belts are designed for team leaders, supervisors, and project managers who are ready to lead department-level changes and support project-based improvements. Black Belt certifications are usually suited for senior managers whose role is to drive cross-functional changes and build continuous improvement.

However, Lean Six Sigma training shouldn’t be the go-to choice for everyone. Candidates who train in the certification must show initiative and strong communication skills, as Lean Six Sigma practitioners usually work across teams to influence change.

Additionally, the employee must be interested in data or process improvement, as the methodology requires a fact-based mindset and curiosity to get to the root cause of issues. Employees who can demonstrate this have a higher chance of success in the program.

Conclusion: Is It Worth It? Final Verdict

Lean Six Sigma training is a certification that pays for itself in many ways. Businesses and employees who learn and adopt lean processes have seen immense benefits in cost reduction, efficiency, and competitive advantage.

At OE Partners, we believe that Lean Six Sigma is a powerful tool for any Australian business. Our accredited programs focus on building practical skills and real-world results, with the resulting IP from the training owned by the company itself.

Interested to learn how Lean Six Sigma can improve your business and professional career? Book a consultation with one of our trainers today to get started.