Project Title:

Defect Reduction - Cadbury’s GEMS (More Chocolaty Rs. 5 Pack)

Business Case: Cadbury’s GEMS (More chocolaty) is sold at Rs. 5 per pack in India. It was
introduced in India in the year 2011 with a target to achieve 20% market share
under demographic market segmentation for age group 4 to 8 years.
Manufacturing defects like count, color, shape, and crack in the pebbles cause
a bad customer experience. This experience negatively impacts the sales where
we estimate drop in sales by 2% per quarter i.e. a potential of Rs. 1.1 Million.
Reduction in defects would result in improved process quality by 4%, reduction
in Cost Of Poor Quality (COPQ) by Rs. 1.2 Million, improved customer experience
by 120 bps, and sustainable profits Quarter On Quarter (QoQ).
Problem 4 Opportunities of Error (OFE) has been identified to measure quality of the pack
i.e. count, color, shape, and crack. 10 packets were sampled by the quality team
Statement: recently and the DPMO and Zst score was 284K and 2.08 respectively. An
anecdote recorded recently from a 6 year old customer is as “I don’t like my
pebbles to be broken and not in shape. My friend got 11 pebbles last week and I
got only 9 and I feel sad”. Production team incurs increased COPQ due to these
defects and they report increased cost. Invariably these defects affect both
internal and external customers.
Project Goal: The goal of this Six sigma project is to reduce the DPMO of Cadbury’s GEMS
(More chocolaty) from 284K to 142K (50% reduction goal) by Dec’ 2021.

Project Team: Project Sponsor: Mr. Manoj Guru

Project Champion: Mr. Rajesh Dhanasekaran
Project Leader: Mr. Anand Srinivasan
Project Partner: Mr. Chetan
Project Team: Mr. Sathish, Mr. Rahul, Mr. Sridhar
Project Project scoping - [Duration - 2 weeks; Target Closure date: 23rd July 2021]
Define phase - [Duration - 3 weeks; Target Closure date: 13th Aug 2021]
Milestones: Measure phase - [Duration - 3 weeks; Target Closure date: 3rd Sep 2021]
Analyze phase - [Duration – 3 weeks; Target Closure date: 24th Sep2021]
Improve phase - [Duration - 6 weeks; Target Closure date: 5th Nov 2021]
Control phase - [Duration - 3 weeks; Target Closure date: 26th Nov 2021]
Project Estimate project impact is: Rs. 2,300,000.
Impact is calculated over COPQ reduction (1,200,000) + Market share potential
impact/benefit: loss (1,100,000).
Financial saving estimate and calculation is validated and signed off by the
Finance controller of the business.
Project Team Validate problem statement and goal - Project Sponsor
Create Communication plan - Project Leader
roles and Select and launch team - Project Leader
responsibilities: Develop measurement plan - Project Leader
Collect baseline data - Project Team
Project review, Mentor, and Coaching - Project champion
Project reporting to leadership - Project Leader