Day 1

_____

Lean Six sigma

______________

- Process improvement
- Improve existing process- Reduce wastage-- efficiency
- Minimizing inventory
- Reducing lead time
- Streamlining and optimising operations
- standard- Quality assurance--- 99.99966%
- Increase customer satisfaction

Why do we need to improve?

To Productivity

---------------------------- COST

Sales Price = Cost price + Margin

Cost of Poor quality

- Rework
- Appriasal
- Prevention

- 1 bottle--- Label missing

Short Term
Long Term
1) I pasted the label-----------------------------------------------Rework---------
Minimum Maximum
2) Quality Inspector---- check each bottle-0------------------------Appriasal
3) Quality Manager--- RCA------------------------------------------ Preventive
Action Maximum Minimum

New Joiner-------- 2 Hours training session-

Failure Cost----- Happens at the

CONSUMER side
IMPROVE-----

KAIZEN....
KANBAN...
5S.....---
TOC-----
PDCA
TPM---
JIT... JIT2... VMI... OR

LEAN
Six sigma?

Statistical method to improve process

During the designing of processes
Structured way of problem solving
-

40 Mins to reach office-------- 20 Mins

- I get up ----- 5 Mins

- I freshen up---- 5 Mins-----------------
- Put on clothes---- 5 Mins

- Travel-----------10 Mins

40 Mins---------------------------25 Mins

Clubing... Remove... ELiminating----- LEAN

PSA---- Do not require any DA--- experience based solutions----- Judgment based
solution

1) 5S
2) PSA-- Do not require DA
JIT.. VMI...PDCA.. TOC.. TPM...
3) Lean Methodology------------------- Waste elimination
4) Six Sigma----------------------------- Variation reduction------ Increasing the
consistency
5) ML/ AI

Experince------ Data fact

350-----

More data points-------- Measurement system... Smapling..

300
350
360
400
280

Six Sigma

Six Sigma practioniner-- doctor for processes

Problem-- Stomach ache Problem---

Examine-- Diagnose-- question understand the process

List of causes-- eliminating the causes List of causes----
elinminate the cuases

Stone
Stomach ulcer
Cancer
Any other

TESTS---------------------- ------------ TESTS------

STatistical test----
IMPROVE---- VALIDATED CAUSE

2 Frameworks
DMAIC- Define-- Measure-- Analyze-- Improve-- Control
- Existing process
- Capability enhancement
 DMADV-- Define-- Measure... Analyse--- Design... Verify
- NEW process
- Capacity Increment

Develop... Validate
IDOV---- Initiate develop.. Observe.. Validate
IMDOV---- initiate.. measure.. Develop... Observe.. Validate
DFSS---- design for Six sigma

DMADVO--- OPTIMIZE

Capability--- Capacity + Ability

Car--- TOP SPEED--- 300 KMPH---------CAPACITY

220 KMPH------------250--------- DMAIC

250------------------290---------DMAIC
290------------------------330--------DMADV

1) Data is a constraint
2) CAPEX management depedent

Yellow
Green Belt--- introduces
Black--------------- Implementation
Master black belt--- able to train

99.99966%

Global acceptance

yellow/ White------ 4 hours of Quality Training session

Jurisdiction/ hierarchy

IMPORTANCE of cases

GB--- IMPLEMENT
BB----COACH / Mentor/ Train...... Statistcal Understanding
MBB------------------------------- Change Managemnet approaches

APEX COUNCIL--- Corporate--- SOP// Template.. Trainig.... Certification... Project

management
Process owner---- HOD--

40 Mins------ 20 Mins

COSt of Poor quality-- Potential Loss

1000000--- GB/ BB/ MBB

- COst Savings
- % change in KPI----

Pre requisites
- Repetitive
- QUantifyable
- Root Causes/ Solution should not be known at the start of the project

$25K------- GB
$250K-------BB
$500K------MBB

100000--- 2 Projects----- GB--- 2 Years

300000------2 Projects---- BB---2 years
5 00000 -------2 Project-------3 -- MBB

STARt of the project---- GB.. BB... MBB project SAME

Hisotry of six sigma

Motorola 1986-- BAndit

GE---- 1995---- $2 bn

MAIC
 DEFINE---

INSURANCE

20-80

First 9 Months---- 20%

Last quarter----80%

1) January

15 Months------Problem with revenue-----10000 Rs per day

------------------------2000 per day

Seasonality is Known

2) KPMG

30000 People--------30 Days to close perf. evaluation

40000 People---------20 Days

_______________________________________________________________________________

Define---- identification of problem

Measure----- Validate the problem
ANALYZE------- List of Causes--- Validtae the causes
IMPROVE-------- Identify and implenment the improvement
CONTROL------- Sustain and maintain... documentation

DEFINE
_______

1) Identify the project

- Identify the customer--- Internal / External (Regulatery)
- Capture the VOC-- Voice of Customer
- Priortisation
- VOC into CTQ- Critical to Quality--- Quantifyable
 - Priortisation
2) Management Approval
3) Process understanding

- Finding the scope of improvement

- Bottle necks in poerations
- Brainstorming

Hilton Ka CEO
---5 Strategic projects------- Cost reduction

Internal
- receiptionist
- Rude Customers
- Salary is not at
par--------------------------------------------------------------------------------
--
- Working conditions are not good
- linguistic barrier
- Bell boys availability

- Bell boys
- Security staff
- Chefs
- Not enough cutlery
- Waiting staff does not pick up the dishes in time
- Menu dishes is too high

- Waiters
- Absentism
- High load during peak hours
- enough tips
External
- Individuals
- Food is not
tasty--------------------------------------------------------------
- Not value for money
- corporate
- Discounts

- event management companies

- Approach road is not in good
condition-------------------------------------------------
- Vendors
- Do not pay in agreed 60 days term

Priortisation---- Kano Model and Affinity Diagram

- Pareto Chart
- Improtance Vs Urgency------
- Control Impact Matrix
- 9 Square priortisation tool- effort impact matrix
- Kano Model
- ABC method
 14 tools---
- Judgment
- Team consensus
- Data - Pareto

Generic problem into Specific problem-- Quantifyable

WHAT

Food is not tasty-----

Customer Feedback (1-5)
- Food Temp
- Time to serve
- Food qantify
- Quality of ingredient
- Type of crockery

Valid six sigma GB project

health minister in india

- Potable water quality is poor
CTQ-----
TDS
PH Value
Turbidity
Clarity
Smell
# of visible impurities
Colour

CTQE- Cost.. Time.. Quality.... Effort

Manufacturer-----COst