Vasav Krishna

✅ Six Key Metrics for Quality Improvement To achieve excellence in quality, organizations must focus on data-driven decision-making. Here are 6 essential metrics that help monitor and improve product and process quality: 📌 1. Quality Rate The percentage of units produced without defects. > Formula: (Good Units / Total Units) × 100 📌 2. DPMO (Defects Per Million Opportunities) Measures the number of defects per one million opportunities. > Ideal for Six Sigma performance tracking. 📌 3. Rework Percentage Indicates the proportion of products requiring rework. > Lower rework = better first-time quality. 📌 4. Process Capability (Cp) Shows how well a process can meet specification limits. > Cp > 1.33 is typically considered capable. 📌 5. DPPM (Defective Parts Per Million) Measures the number of defective units per million produced. > Useful for supplier and product quality tracking. 📌 6. Process Capability Index (Cpk) Combines process centering and spread to assess how well a process meets customer specs. > Higher Cpk = better performance & consistency. --- 🎯 Tracking these KPIs regularly leads to better quality decisions, reduced costs, and higher customer satisfaction. Which metric do you rely on most in your organization? #quality #qualityassurance #qualitycontrol #qualitymanagementsystem #qualityjobs #qualityengineer #qualityeducation #qualityaudit #qualitytraining #qualityinspection #qms #qaqc #7qctools #qualityengineering #pdca #sixsigma #capa #qualitymanagement #management #training #productivity #engineering #careers #projectmanagement #lean #excellence #engineers #waste #iso #tutorial #kanban #kaizen #iso9001 #leansixsigma #tutorials #leanmanufacturing #5s #mechanicalengineering #msa #oee #industrialengineering #smed #ishikawa #jidoka #pokayoke #andon #7qctools #histogram #qcc #sop #timwood #takttime #pullsystem #kpi #tpm #ppap #coretools #spc #tpm #automotiveindustry #controlchart #iatf16949 #jobinterviews #checksheet #fishbone #g8d #paretochart #vsm #iatf #qms #linebalancing #fmea #vsmstudy #flowchart #histograms #7waste #3mwaste #apqp #smartgoal #DMAIC #Kaizen #5Why #BlackBelt #GreenBelt #YellowBelt

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🔍 Understanding Six Sigma Levels – From 1 to 6 Sigma 🎯 In Quality Management, the Sigma level represents the capability of a process to perform defect-free work. Here's a simplified view from 1 Sigma to 6 Sigma, comparing key metrics: 📊 Sigma Level | Cp Value | Defect Rate (PPM) | Yield (%) | CoPQ | Competitive Level 1️⃣ 1 Sigma → Cp: 0.33 | Defects: 690,000 | Yield: – | CoPQ: 74% | Competitive: ❌ 2️⃣ 2 Sigma → Cp: 0.66 | Defects: 308,537 | Yield: 69.14% | CoPQ: 30–40% | Competitive: ❌ 3️⃣ 3 Sigma → Cp: 1.00 | Defects: 66,807 | Yield: 93.31% | CoPQ: 20–30% | Competitive: 🏭 Industry Average 4️⃣ 4 Sigma → Cp: 1.33 | Defects: 6,210 | Yield: 99.37% | CoPQ: 15–20% | Competitive: 🏭 Industry Average 5️⃣ 5 Sigma → Cp: 1.67 | Defects: 233 | Yield: 99.97% | CoPQ: 10–15% | Competitive: 🌍 World Class 6️⃣ 6 Sigma → Cp: 2.00 | Defects: 3.4 | Yield: 99.99966% | CoPQ: <10% | Competitive: 🌍 World Class 💡 Key Takeaway: As you move from 1 to 6 Sigma: ✔️ Defects drop drastically ✔️ Customer satisfaction increases ✔️ Cost of Poor Quality (CoPQ) reduces ✔️ Your organization moves from non-competitive to world-class! 📈 Six Sigma is not just a quality tool—it’s a competitive advantage! #quality #qualityassurance #qualitycontrol #qualitymanagementsystem #qualityjobs #qualityengineer #qualityeducation #qualityaudit #qualitytraining #qualityinspection #qms #qaqc #7qctools #qualityengineering #pdca #sixsigma #capa #qualitymanagement #management #training #productivity #engineering #careers #projectmanagement #lean #excellence #engineers #waste #iso #tutorial #kanban #kaizen #iso9001 #leansixsigma #tutorials #leanmanufacturing #5s #mechanicalengineering #msa #oee #industrialengineering #smed #ishikawa #jidoka #pokayoke #andon #7qctools #histogram #qcc #sop #timwood #takttime #pullsystem #kpi #tpm #ppap #coretools #spc #tpm #automotiveindustry #controlchart #iatf16949 #jobinterviews #checksheet #fishbone #g8d #paretochart #vsm #iatf #qms #linebalancing #fmea #vsmstudy #flowchart #histograms #7waste #3mwaste #apqp #smartgoal #DMAIC #Kaizen #5Why #BlackBelt #GreenBelt #YellowBelt

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✅ Most Important Six Sigma Terms You Should Know ➡️ Follow Gemba Concepts For Regular Content Updates! Six Sigma is all about process improvement, data-driven decisions, and reducing variation. Here are the key terms every professional should be familiar with: 🔹 DMAIC – Define, Measure, Analyze, Improve, Control (problem-solving methodology for process improvement). 🔹 DMADV – Define, Measure, Analyze, Design, Verify (used for designing new processes or products). 🔹 Defect – Any instance when a process fails to meet customer requirements. 🔹 DPMO (Defects Per Million Opportunities) – A measure of process performance and error rate. 🔹 Process Variation – Differences in process outputs, often the root cause of inefficiencies. 🔹 CTQ (Critical to Quality) – Key characteristics most important to the customer. 🔹 Sigma Level – Statistical measure of process capability (higher sigma = fewer defects). 🔹 VOC (Voice of Customer) – Capturing customer expectations and requirements. 🔹 FMEA (Failure Mode and Effects Analysis) – Tool for identifying and prioritizing risks. 🔹 Root Cause Analysis – Identifying the true cause of a defect or problem. 🌟 Mastering these terms is the first step toward understanding Six Sigma methodology and applying it effectively in business transformation. 💬 Which Six Sigma term do you use most in your daily work? #SixSigma #ProcessImprovement #QualityManagement #LeanSixSigma #ContinuousImprovement

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MASTER CI - CHEAT SHEET   Master Continuous Improvement to keep your business ahead in 2025. Go from zero to pro with the ultimate CI cheat sheet:   1/ PDCA   PDCA is a four-step model for Lean problem-solving and change management.   This framework enables you to solve problems in a rigorous, methodical way.   It's a key CI tool in different areas like   +problem solving +quality management +new product development +business process management   It enables you to implement the best solutions.   *** 2/ Value Stream Mapping   VSM is a visual tool that shows all critical steps in your operations from material inputs to customer delivery.   It aims to show you where you can reduce waste.   Main steps are:   +Pick a product family +Build the VSM team +Figure out your customer demand +Map the material flow +Map the information flow   *** 3/ Kanban   Kanban is a scheduling system for lean manufacturing that originated at Toyota in the 1950s.   It's used to manage and improve the flow of work, with the goal of minimizing waste and maximizing efficiency.   A Kanban board is a visual tool used to manage and optimize the flow of work.   It consists of columns, cards and swimlanes.   *** 4/ Poka Yoke   Poka-Yoke is a Japanese term that means "mistake-proofing".   It refers to any mechanism helping an operator avoid mistakes by preventing, correcting, or drawing attention to human errors as they occur.   *** 5/ 5S   5S refers to 5 Japanese terms which are used to describe the main steps of visual management toward OpEx:    -1S- Seiri → Sort -2S- Seiton → Set In Order -3S- Seiso → Shine -4S- Seiketsu → Standardize -5S- Shitsuke → Sustain   When successfully implemented, 5S can turn any dirty place into a clean, standardized workplace.   *** 6/ Gemba Walk   See the reality on the ground, instead of just relying on data.    That’s what the Gemba Walk is all about.   In Japanese, the word ‘Gemba’ → ‘Actual Place.’    If you detect resistance to change, *** We’re pushing ourselves out of our comfort zone by building our first AI-embedded Kaizen toolkit. Meanwhile, you can get here our Gemba Walk checklists to identify more waste and become a trusted Kaizen practitioner. Click here to get exclusive access now: https://lnkd.in/d424c7rX

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MASTER CI - CHEAT SHEET   Master Continuous Improvement to keep your business ahead in 2025. Go from zero to pro with the ultimate CI cheat sheet:   1/ PDCA   PDCA is a four-step model for Lean problem-solving and change management.   This framework enables you to solve problems in a rigorous, methodical way.   It's a key CI tool in different areas like   +problem solving +quality management +new product development +business process management   It enables you to implement the best solutions.   *** 2/ Value Stream Mapping   VSM is a visual tool that shows all critical steps in your operations from material inputs to customer delivery.   It aims to show you where you can reduce waste.   Main steps are:   +Pick a product family +Build the VSM team +Figure out your customer demand +Map the material flow +Map the information flow   *** 3/ Kanban   Kanban is a scheduling system for lean manufacturing that originated at Toyota in the 1950s.   It's used to manage and improve the flow of work, with the goal of minimizing waste and maximizing efficiency.   A Kanban board is a visual tool used to manage and optimize the flow of work.   It consists of columns, cards and swimlanes.   *** 4/ Poka Yoke   Poka-Yoke is a Japanese term that means "mistake-proofing".   It refers to any mechanism helping an operator avoid mistakes by preventing, correcting, or drawing attention to human errors as they occur.   *** 5/ 5S   5S refers to 5 Japanese terms which are used to describe the main steps of visual management toward OpEx:    -1S- Seiri → Sort -2S- Seiton → Set In Order -3S- Seiso → Shine -4S- Seiketsu → Standardize -5S- Shitsuke → Sustain   When successfully implemented, 5S can turn any dirty place into a clean, standardized workplace.   *** 6/ Gemba Walk   See the reality on the ground, instead of just relying on data.    That’s what the Gemba Walk is all about.   In Japanese, the word ‘Gemba’ → ‘Actual Place.’    If you detect resistance to change, *** We’re pushing ourselves out of our comfort zone by building our first AI-embedded Kaizen toolkit. Meanwhile, you can get here our Gemba Walk checklists to identify more waste and become a trusted Kaizen practitioner. Click here to get exclusive access now: https://lnkd.in/d424c7rX

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Discussion about Lean Manufacturing Checklist: 1. Workplace Organization (5S) Sort – Remove unnecessary items from the workplace. Set in Order – Arrange tools, materials, and equipment for easy access. Shine – Keep machines, floors, and work areas clean and maintained. Standardize – Create clear procedures for cleaning, organizing, and storing. Sustain – Conduct regular audits to maintain 5S discipline. 2. Waste Elimination (7 Wastes) Overproduction – Produce only what’s needed, when needed. Waiting – Minimize idle time of workers/machines. Transport – Reduce unnecessary movement of materials. Overprocessing – Avoid redundant or excessive processes. Inventory – Keep stock levels minimal while meeting demand. Motion – Reduce excessive operator movement. Defects – Implement root cause analysis to prevent rework. 3. Flow & Pull Value Stream Mapping – Identify and optimize process flow. One-Piece Flow – Produce one unit at a time where possible. Kanban System – Implement visual pull system to control WIP (Work in Progress). Takt Time – Align production rate with customer demand. 4. Standard Work Written SOPs (Standard Operating Procedures) for each task. Defined work sequence, timing, and quality checks. Operator training and skill matrix tracking. Continuous improvement log for each process. 5. Quality at Source Poka-Yoke (Error Proofing) devices in place. First-piece inspection before mass production. Immediate defect feedback to operators. SPC (Statistical Process Control) in critical processes. 6. Continuous Improvement (Kaizen) Regular Kaizen events/workshops. Employee suggestion program in place. Daily/weekly Gemba walks by managers. PDCA (Plan–Do–Check–Act) cycle applied for all improvements.

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🔍 Understanding Six Sigma Levels – From 1 to 6 Sigma 🎯 In Quality Management, the Sigma level represents the capability of a process to perform defect-free work. Here's a simplified view from 1 Sigma to 6 Sigma, comparing key metrics: 📊 Sigma Level | Cp Value | Defect Rate (PPM) | Yield (%) | CoPQ | Competitive Level 1️⃣ 1 Sigma → Cp: 0.33 | Defects: 690,000 | Yield: – | CoPQ: 74% | Competitive: ❌ 2️⃣ 2 Sigma → Cp: 0.66 | Defects: 308,537 | Yield: 69.14% | CoPQ: 30–40% | Competitive: ❌ 3️⃣ 3 Sigma → Cp: 1.00 | Defects: 66,807 | Yield: 93.31% | CoPQ: 20–30% | Competitive: 🏭 Industry Average 4️⃣ 4 Sigma → Cp: 1.33 | Defects: 6,210 | Yield: 99.37% | CoPQ: 15–20% | Competitive: 🏭 Industry Average 5️⃣ 5 Sigma → Cp: 1.67 | Defects: 233 | Yield: 99.97% | CoPQ: 10–15% | Competitive: 🌍 World Class 6️⃣ 6 Sigma → Cp: 2.00 | Defects: 3.4 | Yield: 99.99966% | CoPQ: <10% | Competitive: 🌍 World Class 💡 Key Takeaway: As you move from 1 to 6 Sigma: ✔️ Defects drop drastically ✔️ Customer satisfaction increases ✔️ Cost of Poor Quality (CoPQ) reduces ✔️ Your organization moves from non-competitive to world-class! 📈 Six Sigma is not just a quality tool—it’s a competitive advantage! #quality #qualityassurance #qualitycontrol #qualitymanagementsystem #qualityjobs #qualityengineer #qualityeducation #qualityaudit #qualitytraining #qualityinspection #qms #qaqc #7qctools #qualityengineering #pdca #sixsigma #capa #qualitymanagement #management #training #productivity #engineering #careers #projectmanagement #lean #excellence #engineers #waste #iso #tutorial #kanban #kaizen #iso9001 #leansixsigma #tutorials #leanmanufacturing #5s #mechanicalengineering #msa #oee #industrialengineering #smed #ishikawa #jidoka #pokayoke #andon #7qctools #histogram #qcc #sop #timwood #takttime #pullsystem #kpi #tpm #ppap #coretools #spc #tpm #automotiveindustry #controlchart #iatf16949 #jobinterviews #checksheet #fishbone #g8d #paretochart #vsm #iatf #qms #linebalancing #fmea #vsmstudy #flowchart #histograms #7waste #3mwaste #apqp #smartgoal #DMAIC #Kaizen #5Why #BlackBelt #GreenBelt #YellowBelt

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DMAIC: The Backbone of Six Sigma Six Sigma projects follow a structured approach. DMAIC (Define, Measure, Analyze, Improve, Control) provides the roadmap to solve problems and drive sustainable improvements. Here’s a simple visual reminder of the 5 stages that keep projects focused and results measurable. At Quality Gurus, we don’t just explain DMAIC; we show you how to apply it with real-world examples, AI-powered tools, and step-by-step guidance. Explore our Six Sigma courses here: https://lnkd.in/gArm6ndj

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🔍 What is Value Stream Mapping (VSM)? Value Stream Mapping is a Lean management tool used to visualize and analyze the flow of materials and information required to bring a product or service to a customer. It helps identify waste, bottlenecks, and improvement opportunities. --- 📌 Purpose of VSM: Understand the current process from end to end Identify and eliminate non-value-added activities (waste) Improve flow, lead time, and efficiency Support continuous improvement initiatives --- 🛠️ Key Elements of a Value Stream Map: 1. Customer Requirements 2. Process Steps (from supplier to customer) 3. Material Flow 4. Information Flow 5. Inventory Levels (WIP) 6. Cycle Time (CT), Lead Time (LT), Takt Time 7. Timeline Bar (Processing Time vs Waiting Time) --- 📊 Types of VSM: Current State Map – Shows how things are done now Future State Map – Envisions an improved, leaner process Ideal State Map – Represents the ultimate efficient process --- 🚦 Common Waste Identified Through VSM (TIMWOODS): Transport Inventory Motion Waiting Overproduction Overprocessing Defects Skills (underutilized talent) --- 🔄 Steps to Create a Value Stream Map: 1. Choose a product or process family 2. Define the boundaries (start to finish) 3. Gather process data (walk the process!) 4. Map the current state (include flow & data) 5. Analyze for waste and inefficiencies 6. Design the future state map 7. Create an action plan to bridge the gap --- 📈 Benefits of VSM: Better understanding of the entire value chain Clear visibility of waste and improvement areas Improved communication and collaboration Foundation for Lean transformation --- 💡 Pro Tip: Always involve cross-functional teams during VSM creation to gain accurate insights and promote ownership of improvements. #quality #qualityassurance #qualitycontrol #qms #qualityaudit #qualityinspection #management #training #productivity #engineering #careers #projectmanagement #lean #excellence #engineers #waste #iso #tutorial #kanban #kaizen #iso9001 #leansixsigma #tutorials #leanmanufacturing #5s #mechanicalengineering #msa #oee #industrialengineering #smed #ishikawa #jidoka #pokayoke #andon #7qctools #histogram #qcc #sop #timwood #takttime #pullsystem #kpi #tpm #ppap #coretools #spc #tpm #automotiveindustry #controlchart #iatf16949 #jobinterviews #checksheet #fishbone #g8d #paretochart #vsm #iatf #qms #linebalancing #fmea #vsmstudy #flowchart #histograms #7waste #3mwaste #apqp #smartgoal #DMAIC #Kaizen #5Why #BlackBelt #GreenBelt #YellowBelt

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MASTER CI - CHEAT SHEET   Master Continuous Improvement to keep your business ahead in 2025. Go from zero to pro with the ultimate CI cheat sheet:   1/ PDCA   PDCA is a four-step model for Lean problem-solving and change management.   This framework enables you to solve problems in a rigorous, methodical way.   It's a key CI tool in different areas like   +problem solving +quality management +new product development +business process management   It enables you to implement the best solutions.   *** 2/ Value Stream Mapping   VSM is a visual tool that shows all critical steps in your operations from material inputs to customer delivery.   It aims to show you where you can reduce waste.   Main steps are:   +Pick a product family +Build the VSM team +Figure out your customer demand +Map the material flow +Map the information flow   *** 3/ Kanban   Kanban is a scheduling system for lean manufacturing that originated at Toyota in the 1950s.   It's used to manage and improve the flow of work, with the goal of minimizing waste and maximizing efficiency.   A Kanban board is a visual tool used to manage and optimize the flow of work.   It consists of columns, cards and swimlanes.   *** 4/ Poka Yoke   Poka-Yoke is a Japanese term that means "mistake-proofing".   It refers to any mechanism helping an operator avoid mistakes by preventing, correcting, or drawing attention to human errors as they occur.   *** 5/ 5S   5S refers to 5 Japanese terms which are used to describe the main steps of visual management toward OpEx:    -1S- Seiri → Sort -2S- Seiton → Set In Order -3S- Seiso → Shine -4S- Seiketsu → Standardize -5S- Shitsuke → Sustain   When successfully implemented, 5S can turn any dirty place into a clean, standardized workplace.   *** 6/ Gemba Walk   See the reality on the ground, instead of just relying on data.    That’s what the Gemba Walk is all about.   In Japanese, the word ‘Gemba’ → ‘Actual Place.’    If you detect resistance to change, *** We’re pushing ourselves out of our comfort zone by building our first AI-embedded Kaizen toolkit. Meanwhile, you can get here our Gemba Walk checklists to identify more waste and become a trusted Kaizen practitioner. Click here to get exclusive access now: https://lnkd.in/d424c7rX

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