A STUDY ON IMPACT OF SIX SIGMA PRACTICES AT HARITA TVS TECHNOLOGIES LTD.

, CHENNAI Six Sigma is a business improvement strategy that seeks to find and eliminate causes of defects or mistakes in business processes by focusing on outputs that are all critical importance to customers. It is a methodology based on statistical thinking and methods. This methodology is used to produce very large improvements in business performance and to produce a lot of bottom line savings. Six sigma projects often focus on improving productivity, process yields, production rates and process down time, which results in enhanced process performance, improved customer satisfaction, increased revenue and bottom line savings. It is a strategic approach that works across all processes, products and industries. The Sigma value of a process describes the quality level of that process. Six Sigma is defined by Motorola, as a quality improvement program with an ultimate goal of reducing the number of defects as low as 3.4 defects per million opportunities. The higher the sigma capability, the better is the performance, because it measures the capability of the process to achieve defect free work. A defect is anything that results in customer dissatisfaction. Six Sigma was originally developed as a set of practices designed to improve manufacturing processes and eliminate defects, but its application was subsequently extended to other types of business processes as well. In Six Sigma, a defect is defined as anything that could lead to customer dissatisfaction. The particulars of the methodology were first formulated by Bill Smith at Motorola in 1986. Six Sigma was heavily inspired by six preceding decades of quality improvement methodologies such as quality control, TQM, and Zero Defects, based on the work of pioneers such as Shewhart, Deming, Juran, Ishikawa, Taguchi and others. Like its predecessors, Six Sigma asserts that ±
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Continuous efforts to achieve stable and predictable process results (i.e. reduce process variation) are of vital importance to business success. Manufacturing and business processes have characteristics that can be measured, analyzed, improved and controlled. Achieving sustained quality improvement requires commitment from the entire organization, particularly from top-level management.

Features that set Six Sigma apart from previous quality improvement initiatives include ±
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A clear focus on achieving measurable and quantifiable financial returns from any Six Sigma project. An increased emphasis on strong and passionate management leadership and support. A special infrastructure of "Champions," "Master Black Belts," "Black Belts," etc. to lead and implement the Six Sigma approach. A clear commitment to making decisions on the basis of verifiable data, rather than assumptions and guesswork.

The term "Six Sigma" is derived from a field of statistics known as process capability studies. Originally, it referred to the ability of manufacturing processes to produce a very high proportion of output within specification. Processes that operate with "six sigma quality" over the short term are assumed to produce long-term defect levels below 3.4 defects per million opportunities

Six Sigma is a registered service mark and trademark of Motorola.26% efficiency Two Sigma = 308. Six Sigma has sometimes been combined with lean manufacturing to yield a methodology named Lean Six Sigma. Sigma levels Taking the 1. Physical Testing & Validation. Inc. about two-thirds of the Fortune 500 organizations had begun Six Sigma initiatives with the aim of reducing costs and improving quality.000 DPMO = 68. as Concept Design.[6] Motorola has reported over US$17 billion in savings[7] from Six Sigma as of 2006. customer complaints. o COMPANY PROFILE Harita TVS Technologies Harita TVS is an Engineering Design Services company catering to Automotive and Construction & Industrial Machinery Energy.9997% efficiency Benefits of Six Sigma The key reasons for implementing Six Sigma are as follows: ‡ To be responsive and to be focused on customer needs.[8] By the late 1990s. Product Engineering. ‡ Improved consistency level of service through systematic reduction of variability in processes.).[4][5] Six Sigma's implicit goal is to improve all processes to that level of quality or better. etc. The company is a part of the prestigious TVS Group and offers end-to-end solutions for next generation products with its Mechanical Design Services (MDS). short-term sigma levels correspond to the following long-term DPMO values (one-sided): y y y y y y y y y y y y y y y y y One Sigma = 690. ‡ Reduced number of non-value added steps in critical business processes through systematic elimination.000 DPMO = 95.24% efficiency Three Sigma = 66.800 DPMO = 99.(DPMO).Transformation of organizational culture from fire-fighting mode to fire-prevention mode. ‡ Reduced Cost Of Poor Quality (COPQ) (costs associated with late delivery. ‡ Increased awareness of various problem solving tools and techniques. ‡ To be able to quantify its quality programs. Harita TVS' service offerings cover the entire spectrum of requirements for any typical µNew Product Development Program¶. ‡ To improve financial performance and business profitability. leading to greater job satisfaction for employees.5 sigma shift into account.73% efficiency Six Sigma = 3. Other early adopters of Six Sigma who achieved well-publicized success include Honeywell (previously known as AlliedSignal) and General Electric. misdirected problem solving. In recent years. . Manufacturing Engineering Services. leading to faster delivery of service. Predictive Engineering (Analysis). Compliance Engineering and Product Consultancy. where the method was introduced by Jack Welch. ‡ Increased employee morale.4 DPMO = 99.

RESEARCH METHODOLOGY . Harita TVS has been able to meet these requirements of its global customers consistently. An excellent Customer Engagement Model & Delivery System driven by Six-Sigma processes has helped Harita TVS maintain an impeccable track record of excellent and on-time delivery. Europe & India for their Engineering Service requirements. To Improve or optimize the process based upon data analysis using techniques like Design of experiments. Determine what the relationships are. y y y y To Define process improvement goals that are consistent with customer demands and the enterprise strategy. and attempt to ensure that all factors have been considered. Harita TVS has become a preferred partner for many global OEM & Tier-1 customers across USA. set up control mechanisms and continuously monitor the process. Within few years of formation. helps keep pace with the growing needs of customers across different geographies in varied markets. Compliance Engineering and Product Consultancy. helping them to reach their strategic business goals by reducing time-to-market and cutting costs.2 OBJECTIVES OF THE STUDY To ensure that the impact of Six Sigma practiced should make the following objectives. Physical Testing & Validation.Within few years of formation. as Concept Design. Harita TVS is an Engineering Design Services company catering to Automotive and Construction & Industrial Machinery Energy. The company is a part of the prestigious TVS Group and offers end-to-end solutions for next generation products with its Mechanical Design Services (MDS). Harita TVS' service offerings cover the entire spectrum of requirements for any typical µNew Product Development Program¶. Set up pilot runs to establish process capability. Harita TVS has been able to meet these requirements of its global customers consistently. Harita TVS has become a preferred partner for many global OEM & Tier-1 customers across USA. move on to production. Europe & India for their Engineering Service requirements. A highly competent & creative talent managed by PCMM. To Analyze the data to verify cause-and-effect relationships. 3. 1. Harita TVS is ISO 9001:2000 certified and is on path to get certified for ISO 27001. To Control to ensure that any deviations from target are corrected before they result in defects. helping them to reach their strategic business goals by reducing time-to-market and cutting costs. Manufacturing Engineering Services. Product Engineering. Predictive Engineering (Analysis). To Measure key aspects of the current process and collect relevant data.

Meaning of stratified random sampling If a population from which a sample is to be drawn does not constitute a homogenous group. SAMPLING DESIGN In this study the researcher used stratified random sampling. data collection methods. websites. RESEARCH DESIGN Research design was based on descriptive research. survey.  The research methodology in the present study deals with research design. questionnaire Secondary Data It means data that are already available ie. analysis and interpretation and limitations of the study. magazines were widely used. they refer to the data which have already been collected and analysed by someone else. STATISTICAL TOOLS USED PERCENTAGE OF ANALYSIS . company report. Research methodology is a way to systematically solve the research problem  It may be understood as a science of studying how research is done scientifically. DATA COLLECTION Primary Data Primary data either through observation or through direct communication with respondent in one form or another. From the population the researcher took the sample size of 92. stratified sampling technique is generally applied in order to obtain a representative sample. The primary data was collected from the employees. ³A research design is the arrangement of conditions for collections and analysis of data in a manner that aims to combine relevance to the research purpose with economy in procedure´. sampling methods. The secondary data was used to support primary data. through structured which is given in the annexure.

Second Edition.Kothari. X = the variable values i. New Age international Publishers. of.e. Weighted average method gives the result equal to the simple mean if the weights assigned to each of the variable values are equal.2002 Second Edition. Percentage = No.R.e. W2«Wn respectively. X2«Xn REFERENCES C. Multiply the weights by the variable x and obtain the total §wx. The weights attached to each item being proportional to the importance of the item in the distribution. X1. Respondents Total no of samples WEIGHTED AVERAGE METHOD Proper weight age is to be given to various items. W1. . Research Methodology Methods & Techniques. Divide the total by the sum of the weight §w Weighted average mean = § WX §W W = the weights attached to variable values i. Percentages are used to make comparison between two or more series of data. It is used to describe the relationship comparison of absolute figure that is difficult to compute interpret. 2..Percentage refers to a specific kind of ratio. The steps to be followed: 1.

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Geoff (2001). As a non-parameter test. ISBN 0566083744. as x is a statistical measure used in the context of sampling analysis for comparing a variance to a theoretical variance. Aldershot.Tennant. CHI-SQUARE TEST written Chi-square symbolically. SIX SIGMA: SPC and TQM in Manufacturing and Services. It is calculated as follows: Where Ei Oi= Observed Frequency § ?O G 2 cal ! i  Ei A 2 Ei= Expected frequency Expected frequency=Row total for the row of that cell x column total of that cell Grand total . it can be used to determine if categorical data shows dependency or the two classifications are independent. Ltd. UK: Gower Publishing.

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