Breakthrough projects help organisations to systematically solve complex process problems and achieve demonstrable improvements.
Symbol trains and coaches Green Belts, Black Belts, and Champions in selecting, executing, and embedding breakthrough projects using the DMAIC approach.
Breakthrough projects are larger improvement projects for complex process problems that cannot be solved with simple improvement actions. These often involve problems with a structural impact on quality, costs, lead time, customer satisfaction, or process performance.
Within CIMM Level 4, breakthrough projects are used to make processes more capable. This means that process variation is reduced, causes of quality problems are investigated, and improvements are substantiated with data.
The DMAIC approach forms the project structure for these breakthrough projects. Through Define, Measure, Analyze, Improve, and Control, teams work step-by-step from problem definition to sustainable embedding. Such projects often last several months and are usually led by a Green Belt or Black Belt.
A breakthrough project follows the structured DMAIC approach. This helps teams to solve complex problems not based on assumptions, but with facts, data, and a clear project structure.
In the Define phase, the problem, objective, scope, and project team are recorded in the project charter. Customer needs are translated into measurable CTQs, while impact, lead time, and financial value (COPQ) are also substantiated and aligned.
During the Measure phase, it is determined how the CTQ can be reliably measured. The measurement system is validated, definitions and data sources are recorded, and the difference between baseline and target performance is objectively established.
In the Analyze phase, the team investigates which process factors influence the CTQ and variation. Potential causes are identified, screened, and validated with data, for example, through hypothesis testing, DOE experiments, Value Stream Mapping, or Data analyses.
During the Improve phase, the team develops, selects, and implements solutions for validated causes. The new working method is tested, optimised, and verified with data, so that performance demonstrably improves and waste structurally decreases.
In the Control phase, achieved results are sustainably embedded with, for example, Poka Yoke, standards, work instructions, training, and adapted quality documents. Performance and savings are monitored, after which the project is formally handed over to the Champion.
A successful Six Sigma implementation process begins with selecting suitable projects that align with strategic objectives and offer demonstrable improvement opportunities.Subsequently, employees are trained as Yellow, Green, or Black Belts, appropriate to their role, experience, and responsibility. They learn to systematically investigate and improve process problems using DMAIC, data, and statistical techniques.
Symbol supports selection, provides practical training, and coaches project teams during execution. In this way, methods are directly applied to current issues and results are sustainably embedded.
Within CIMM Level 4, breakthrough projects demonstrably contribute to better, more stable, and more predictable process performance within the entire organisation and support a learning improvement culture.
Symbol helps organisations to select breakthrough projects. During project execution, Green and Black Belts are coached by experienced Master Black Belts. In this way, complex problems are solved data-driven.