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Guidelines for the Session

Guidelines for the Session
 Guidelines for the Session

Please respect others Let’s Be Punctual Have Fun and

Mobile: Off/Silent One voice at a time opinion Participate

Structure of the Training

● Before the Module: Purpose
● After the Module: What all learned
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Trainer - Consultant - Career Coach

…..Growing Together…..

Vasant Pattar - Founder & CEO

www.yashaswiconsultants.com
 VASANT PATTAR
Executive Summary
VASANT PATTAR is having 23 years of rich industrial experience in reputed Birla groups and MNCs in manufacturing
sectors with expertise in Shop floor Management, Quality Management, Systems Management and Continual
Improvements.
q He is currently working as Founder & CEO of YASHASWI CONSULTANTS , to help in the growth of businesses by
effective implementation and hand holding of Lean Manufacturing concepts like TQM, TPM, Six Sigma , Zero Defects
approach, 5S, Kaizen, IATF 16949 , ISO 9001, ISO 14001, ISO 45001 etc.
q Training Expertise :
• He conducts both Online & Onsite trainings in industries and educational sectors.
• Trained more than 5000 participants in both Technical Skills & Soft Skills in different domains such as Automobile,
Qualifications : Aviation, Foundry, Educational, Pharma, Chemical, Textiles, Garments etc.
• Organizing Campus to Corporate trainings for Engineering / MBA students to enhance their employability chances
• B.Tech with University
and make them Industry Ready.
Topper.
q Technical Expertise :
• Certified ISO Auditor for
IATF 16949:2016 (AQMS) ● His strength lies is training, developing & implementing easy to operate systems , effective problem solving, acting as a
ISO 9001(QMS), change agent to bring positive changes in organizations.
ISO 14001(EMS) & ● He focuses on developing a sense of ownership, motivation level and participation of people in achieving the company
ISO 45001(OHSMS) goals and building a culture of continuous improvements.
ISO 21001:2018 (EOMS) ● Certified Family Business Advisor by Indian School of Business (ISB), Hyderabad.

• International Certified q Projects :

Career Coach. ● Companywide implementation of Total Quality Management (TQM) in Century Enka Limited Pune
(Birla Group) and Soktas India Pvt Ltd , Kolhapur (Turkish MNC later taken over by Aditya Birla
• CII Jury
Group) which helped in the transformation of the companies.
• TQM Facilitator. • Handled many six sigma projects which resulted in substantial improvements in Productivity , Quality , Cost & Delivery.

VASANT PATTAR believes in “ Growing Together ”

Introduce yourself…..
1) Name
2) Location
3) Qualification
4) Profession , Designation , Organization
5) Experience
6) Self Investment / Sponsored by the company?
7) Expectations from this Training
8) How did you choose Henry Harvin course?
Let the Course Begin...
Lean Six Sigma-Green Belt
Day 1 10
 What we will learn in this SSGB Course ?
8.00 Pm – 11.00 Pm Break Time : 9.30 Pm – 10.00 Pm.
Day 1 Evolution & Introduction to Lean Six Sigma
Six Sigma Levels .
Day 2 What is Quality ? Why Quality ? Who is Customer ?
What is Process ? What is Problem ?
What is Problem ?
Day 3
Various Problem Solving Tools
Day 4 Lean Manufacturing
Day 5 Lean Manufacturing
Day 6 Basic Statistics / DMAIC : Define
Day 7 DMAIC : Measure , Analyse
Day 8 DMAIC : Improve , Control
Day 9 Total Review / Q&A / Conclusion 11
Module 1
Evolution & Introduction
to Lean Six Sigma
12
Consistency is important, not the average performance…..

4 1 Close to target,
Close to target,
Less variation High variation

(Best (Bad
Performance) performance)

Which is the best

3 performance & 2
Away from
Why ? target, High
Away from
target, Less variation
variation (Worst
(Second Best, performance,
Easy to most difficult)
correct)

4-3-1-2 13
Consider one more example…. Scores of 3 batsmen

14
15
Consider one more example…. Heart Beat

Hear Beat
Numbers Person A Person B Person C

A 105 95 90
B 45 15 70
C 90 140 60
D 60 50 80
Total 300 300 300
Mean 75 75 75
Min 45 15 60
Max 105 140 90
Diff 60 125 30

Std Deviation 27 54 13
Good Worst Best

16
What is
Six Sigma?

17
What is Sigma?

σ Level Defects / Million Fresh %

1σ 693000 30.70
2σ 308550 69.15
3σ 66811 93.32
4σ 6210 99.38
5σ 233 99.98
6σ 3.4 100.00
18
What is Sigma?

How close are you to meet your target?

➢ Sigma is a letter in the Greek Alphabet

➢ Sigma is a Symbol which shows the degree of variation in a
process (standard deviation)
➢ As an upper case letter (∑), it is used as a symbol for sums and
series in which each term is computed from the previous one by
adding (or subtracting) a constant Sigma is used to add all parts,
in sequence, to give a total made up of every number in the
sequence

19
Normal Distribution – BELL Curve

99.73

95.44

68.26

20
Normal Distribution – BELL Curve

99.73

95.44

68.26

Height of the People

21
21
News Paper Delivery 6 Sigma Performance

22
Six Sigma - A Breakthrough Strategy

➢A Business Management Strategy developed by Bill Smith (Father of Six sigma) Motorola,
USA, 1981
➢It is a methodology for continuous improvement
➢It is a set of statistical and other quality tools arranged in unique way
➢A Problem Solving technique , Statistical Approach, A Quality Philosophy, Out of Box thinking
➢Applied to existing processes and products
➢Improves the quality of process outputs by identifying and removing the causes of defects
(errors) and minimizing variability in manufacturing and business processes
➢Accuracy: 99.9997% free of defects(3.4 defects per 1 million)

We gain a competitive edge in Quality, Cost, Customer Satisfaction

23
Fundamental Définition

➢ The fundamental definition of Six Sigma capability refers to a process where "the center of
the process is away from the nearest specification limit by six standard deviations of the
process"
➢ It is a set of statistical and other quality tools arranged in unique way
➢ It is a way of knowing where you are and where you could be!

24
Origin of Six Sigma

MOTOROLA - The company that invented Six Sigma

➢ The term “Six Sigma” was coined by Bill Smith, an engineer from
Motorola

➢ Late 1970s- Motorola started experimenting with problem solving

statistical analysis

➢ 1987- Motorola officially launched it’s Six Sigma program

25
The Growth of Six Sigma

GE - The company that perfected Six Sigma

➢ Jack Welch launched Six Sigma at GE in Jan, 1996

➢ 1998/99- Green Belt exam certification became the criteria for

management promotions

➢ 2002/03- Green Belt certification became the criteria for promotion to

management roles

26
Six Sigma Results

Company Annual Savings

General Electric $2.0+ billion
JP Morgan Chase *$1.5 billion (*since inception in 1998)
Motorola $ 16 billion (*since inception in 1980s)
Johnson & Johnson $500 million
Honeywell $600 million

Six Sigma Savings as % of revenue vary from 1.2 to 4.5 %

For $ 30 million/yr sales – Savings potential $ 360,000 to $ 1.35 million.

27
Quality Pioneers

Importance of understanding variation in work processes Role of management in

leading for quality Application of statistics and Plan-Do-Check-Act.
Edward Deming

Breakthrough performance and Pareto effect Importance of management principles

Quality by design and planning.
Joseph Juran

Customer requirement is performance standard Quality maturity is a journey

Preventive action as basic approach.
Philip Crosby

Cost of poor quality is loss to society as a whole Robust quality is designed for

Genichi Taguchi consistent production Design control is more important than production control.

28
Where can Six Sigma be applied?

Service
Design
Management

Purchase

Six Sigma
Administration Methods Production

Quality Depart
IT

HRM M&S

29
Problem solving strategy

The Problem Solving Methodology focuses on:

➢ Understanding the relationship between independent variables and the dependent variable.

➢ Identifying the vital few independent variables that effect the dependent variable.

➢ Optimizing the independent variables so as to control our dependent variable(s).

➢ Monitoring the optimized independent variable(s).

There are many examples to describe dependent and independent relationships.

➢ We describe this concept in terms of the equation:

Y=f (Xi)
This simply states that Y is a function of the X’s. In other words Y is
dictated by the X’s.
30
Conventional strategy

Y=f (Xi)

Crusher Yield = f ( Feed , Speed , Material

Type , Tool
Wear , Lubricant )
Time to Close
=f( Trial
Balance ,
Correct
Accounts ,
Sub
Accounts ,
Credit
Memos ,
Entry
Mistakes ,X )
n
Applied

If we are so good at the X’s why are we constantly testing and

inspecting the Y?

31
Six Sigma strategy
(X1)
• We use a variety of Six Sigma tools to help separate the “vital few” (X10) (X4)
variables effecting our Y from the “trivial many.”
• Some processes contain many, many variables. However, our Y is not
effected equally by all of them. (X7) (X8)
• By focusing on the vital few we instantly gain leverage.
(X3) (X5)

Archimedes said: “ Give me a lever big enough and fulcrum on which to place it and I shall (X9)
move the world.”

(X6)
(X2)
Archimedes not shown
actual size!

32
Breakthrough strategy

Bad 6-Sigma
Breakthrough UCL

Old Standard
Performance
LCL

UCL
New Standard
LCL
Good

Time Juran’s Quality Handbook by Joseph Juran

By utilizing the DMAIC problem solving methodology to identify and optimize the vital few variables we will realize
sustainable breakthrough performance as opposed to incremental improvements or, even worse, temporary and non-sustainable
improvement.
33
Six Sigma: Challenges and Misconception

Here is a close look at some misconceptions about Six Sigma:

• It is just for manufacturing

• Proper implementation needs a statistical genius
• Six Sigma needs heavy investment on resources and systems
• It can be used only to handle big projects
• It can be done part time
• It needs only a clear understanding of statistical packages
• It can be used to solve day-day problems in processes

34
35
Training is an Investment or an Expense ?
Training is the MOST Important part for GROWING a Business
Employees who don’t Perform
Need Training , not Termination

Without Training After Training

Develop the Skills , Shape your Future
What did we discussed Today ( Day 1) ?

38
What we will be learning Today (Day 2 ) ?

Day 1 Evolution & Introduction to Lean Six Sigma

Six Sigma Levels .
Day 2 What is Quality ? Why Quality ? Who is Customer ?
What is Process ? What is Problem ?
What is Problem ?
Day 3
Various Problem Solving Tools
Day 4 Lean Manufacturing
Day 5 Lean Manufacturing
Day 6 Basic Statistics / DMAIC : Define
Day 7 DMAIC : Measure , Analyse
Day 8 DMAIC : Improve , Control
Day 9 Total Review / Q&A / Conclusion 39
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