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

Watson-Marlow Bredel: £78k cost savings through continuous improvement

Watson-Marlow Bredel wanted to grow in improvement maturity, but the internal GEM programme had been sidelined. Symbol guided the process with a CIMM assessment, Hoshin Kanri sessions and Lean training for the entire organisation. Result: £78,000 cost savings and 200 man-hours saved in 2021, and an organisation on its way to the highest GEM maturity level.

Peka Kroef: Lean Green Belt Training Leads to Tangible Improvement Projects

Peka Kroef had an improvement team but lacked knowledge of Lean methodologies. Symbol provided an in-company Lean Green Belt training for 10 employees from various departments. Result: water consumption reduced, higher production per man-hour, and employees who link improvement projects to organisational objectives themselves. Peka Kroef now has true ambassadors of continuous improvement.

ZGT: Continuous Improvement Across 50 Departments with Lean Six Sigma

ZGT is building a culture of continuous improvement: improvement teams in every department, two project weeks per year, and trained Green Belts. Symbol guides the process. Result: 22 active improvement teams, a 75% success rate for the Green Belt, and a snowball effect of improvements throughout the organisation.

Thales: Lean transformation of radar production

Lean transformation within 22 departments resulted in a 30% shorter lead time and less work in progress. Symbol implemented Lean fundamentals consisting of 6S, WIP control and visual management across 22 departments.

GGD: vaccination speed increased based on Lean

GGD GHOR had to triple the vaccination rate in a short period of time. Symbol formed a Lean team of five consultants who visited 50 vaccination locations in 6 weeks and implemented targeted improvements. Result: the vaccination rate rose from 22 to 100 jabs per hour per line and the weekly volume grew from 500,000 to 1.4 million jabs.

Sealed Air: £100k annual savings through Lean Six Sigma

Sealed Air starts with Lean Six Sigma at the Enschede site: 16 employees trained and four improvement projects launched. The Mixing project delivers €100,000 savings per year and was internationally nominated. Enschede serves as a pilot for a European roll-out and more than 10 employees have signed up for further training.

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.