Continuous Improvement with Lean Six Sigma

Continuous Improvement (CI) is effectively achieved through the application of Kaizen, Lean, and Six Sigma. Its application ensures shorter lead times, lower costs, higher quality, and more stable, predictable processes.

Symbol is an expert in Kaizen, Lean, and Six Sigma, and supports organisations in improving process performance and achieving higher productivity.

Guidance on Continuous Improvement

The Importance of Continuous Improvement

Organisations that do not actively pursue Continuous Improvement risk falling behind. Problems recur, performance stagnates, and improvement opportunities are missed, while the environment is constantly changing.

Low Productivity

Because waste, inefficiencies, and unnecessary activities are not addressed.

Rejection and Customer Complaints

If the root causes of rejections and complaints are not addressed structurally, problems will recur and customers will leave.

Declining Competitive Position

If the organisation does not continuously improve, it will fall behind. This impacts its market position, as well as its ability to attract and retain good employees.

The Result of Continuous Improvement

Improved Quality and Shorter Lead Times

Through Kaizen (continuous improvement), Lean (elimination of waste), and Six Sigma (reduction of variation), the causes of errors are addressed structurally, leading to consistent quality and shorter lead times.

Higher Customer Satisfaction

More stable processes and better quality (Six Sigma), combined with continuous optimisation (Kaizen), lead to a reduction in complaints and an increase in customer satisfaction and trust.

Lower Operational Costs

Lean eliminates waste in processes, while Kaizen and Six Sigma reduce inefficiencies and errors. This results in lower operational costs and better utilisation of resources.

“Perfection is not achieved in one step, but through continuous improvement.”

Continuous Improvement is not a project, but a way of working.

Our approach to Continuous Improvement leads to a daily improvement culture (Kaizen) on the shop floor and to Lean Six Sigma breakthrough projects that contribute to strategic objectives.

Kaizen

Kaizen is a continuous improvement philosophy that involves implementing small, structural improvements in short cycles. Through Gemba Walks, insights are gained on the shop floor, after which improvement opportunities are addressed in targeted PDCA (Plan-Do-Check-Act) projects. Focused problem-solving is applied to find and resolve the causes of problems.

Kaizen

Lean

Lean focuses on creating maximum customer value by prioritising the elimination of waste. Value Stream Mapping provides end-to-end insight into processes. Through Bottleneck Management (TOC), capacity constraints are specifically addressed, improving flow, increasing performance, and making the organisation sustainably more efficient and agile.

Lean

Six Sigma

Six Sigma is a data-driven improvement approach focused on quality and predictable performance. Through DMAIC projects, the causes of deviations are addressed structurally, and the reduction of variation is prioritised. With Design for Six Sigma, processes and products are robustly designed from the initial phase, preventing errors.

Six Sigma

How Continuous Improvement Works in Practice

Thales: Lean transformatie radarproductie

Lean-transformatie binnen 22 afdelingen resulteerde in 30% kortere doorlooptijd en minder onderhandenwerk. Symbol implementeerde Lean-fundamentals bestaande uit 6S, OHW-beheersing en Visual management binnen 22 afdelingen.

Watson-Marlow Bredel: 78k kostenbesparing door continu verbeteren

Watson-Marlow Bredel wilde groeien in verbetervolwassenheid maar het interne GEM-programma was ondergesneeuwd geraakt. Symbol begeleidde het traject met een CIMM-assessment, Hoshin Kanri-sessies en Lean-trainingen voor de hele organisatie. Resultaat: €78.000 kostenbesparing en 200 manuren bespaard in 2021, en een organisatie op weg naar het hoogste GEM-volwassenheidsniveau.

ZGT: continu verbeteren op 50 afdelingen met Lean Six Sigma

ZGT bouwt aan een cultuur van continu verbeteren: verbeterteams op elke afdeling, twee projectweken per jaar en opgeleide Green Belts. Symbol begeleidt het traject. Resultaat: 22 actieve verbeterteams, een slagingspercentage van 75% voor de Green Belt en een sneeuwbaleffect aan verbeteringen door de hele organisatie.

GGD: vaccinatiesnelheid verhoogd o.b.v. Lean

GGD GHOR moest het vaccinatietempo in korte tijd verdrievoudigen. Symbol formeerde een Lean-team van vijf consultants dat in 6 weken 50 vaccinatielocaties bezocht en gerichte verbeteringen doorvoerde. Resultaat: het priktempo steeg van 22 naar 100 prikken per uur per priklijn en het weekvolume groeide van 500.000 naar 1,4 miljoen prikken.

Peka Kroef: Lean Green Belt training leidt tot concrete verbeterprojecten

Peka Kroef had een verbeterteam maar miste kennis van Lean-methodieken. Symbol verzorgde een incompany Lean Green Belt-training voor 10 medewerkers uit verschillende afdelingen. Resultaat: waterverbruik gereduceerd, hogere productie per manuur en medewerkers die zelf verbeterprojecten koppelen aan organisatiedoelstellingen. Peka Kroef heeft nu echte ambassadeurs van continu verbeteren in huis.

Sealed Air: 100k jaarlijkse besparing door Lean Six Sigma

Sealed Air start met Lean Six Sigma in de vestiging in Enschede: 16 medewerkers opgeleid en vier verbeterprojecten gestart. Het Mixing-project levert €100.000 besparing per jaar op en werd internationaal genomineerd. Enschede fungeert als pilot voor een Europese uitrol en meer dan 10 medewerkers hebben zich aangemeld voor een vervolgopleiding.

Results and Impact of Continuous Improvement

Applying Kaizen, Lean, and Six Sigma within the continuous improvement process delivers tangible results for the organisation, employees, and customers.

Higher Product Quality

By reducing variation, defects decrease by 20–50%, first-time-right rates increase, and complaints and rework costs significantly decrease.

Shorter Lead Times

Eliminating waiting times shortens lead times by 30–70%, enabling faster delivery and increased flexibility.

Higher Productivity

More efficient processes lead to a 10–40% productivity improvement, with increased output without additional resources or capacity.

Higher Customer Satisfaction

Fewer errors and faster delivery increase customer satisfaction and can reduce complaints by 30–60%.

Lower Operational Costs

Less waste and fewer errors lead to a 10–30% cost reduction, for example, through less scrap, rework, and more efficient use of materials and capacity.

Take Continuous Improvement to the Next Level

Continuous Improvement is a strategic investment that pays for itself many times over, often yielding 5 to 10 times the return thanks to more efficient processes, less waste, and higher quality.

Symbol supports organisations in developing a strong improvement culture. We train and coach employees in Lean, Six Sigma, and Kaizen.

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: Continuous Improvement is an approach where organisations continuously improve processes to enhance quality, reduce costs, and structurally improve performance.
: Lean focuses on eliminating waste and accelerating processes, while Six Sigma reduces variation and improves quality through data analysis.
: Lean and Six Sigma provide methodologies and tools to continuously improve processes, remove inefficiencies, and make performance measurable and predictable.
: Continuous Improvement leads to lower costs, higher quality, shorter lead times, fewer errors, and increased customer satisfaction, often with measurable improvements within a few months.
: Begin by analysing processes, setting clear KPIs, and initiating small improvement initiatives using Lean or Six Sigma methodologies.