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o What is Lean Six Sigma…

                       o Why Lean Six Sigma…

                           o How we do…

                            o When to do




Journey Towards Operational Excellence…..
                                                 1
Lean Six Sigma is a Business Management Strategy …

 Seeks to identify and remove the causes of defects and errors
 Uses a set of management methods, including statistical
methods
 Creates a high performing culture within the organization



Aims To Deliver Breakthrough Performance In Business Or Operational Measures Like


             Customer Satisfaction Rating Score

 Cost of executing a business process transaction

                                            Billing and Cash Collection lead time

            Yield (Productivity) of service operations or production

                          “When you are finished changing, you're finished.”
                                                                    Benjamin Franklin
                                                                                    2
...Features that clearly distinguish Lean Six Sigma from other quality methodology

                                Six Sigma Lean is a
   Motorola has
   reported over          rigorous, data-driven, result
      US$17                    oriented approach to
     billion in               process improvement.
   savings from
                               It helps in improving
   Six Sigma as
      of 2006              quality, efficiency & speed
                           in every aspect of business


                1)   Ability to distinguish the problems and symptoms
                2)   Structured approach to problem solving
                3)   Root cause analysis for permanent fixes
                4)   Leverage the tools, techniques and best practices for data analysis and
                     solution

                  1)   Able to achieve growth through increased productivity
                  2)   Achieve great customer satisfaction
                  3)   Improves employee engagement & satisfaction
                  4)   Creates an overall high performing culture within the organization
                  5)   Gives a competitive edge in the market place


                                 “It is not enough to do your best; you must know what to do, and
                                 then do your best “                            - Deming
Company Confidential                                                                           3
Defining Road map




Institutionalizing                                         Yellow Belt
                                                           Training &
 Lean Six Sigma                     Monitor               Certification
      Culture


                                   Train

   Black Belt
                                                        Organizational
   Training &                 Consult                    Framework
  Certification




                                    Green Belt
                                    Training &
                                   Certification



                     Our objective is to create value proposition & business
                     outcomes through six sigma consulting…                    4
1
                       •Define Goals & objectives                                 Lean/Six Sigma
                       •Discussions on current issues                             Program Rollout
        Define
                       •Why Six Sigma ( benefits)                                Employee Training plan
    Lean Six Sigma     •Training & Certification criteria; Role definition       Six Sigma/Lean
       Strategy        •Benefits Realization & Review Mechanism                   Training Calendar
                       •Establish communication plan and channels for rollout    Employees/Stakeholder
                                                                                  notification
2
    Lean, Six-sigma    •Six Sigma Awareness & LEAN                               Lean/Six Sigma
                                                                                   awareness across the
      Yellow Belt      •Training duration - 1 day; 7 hours training & 1 hour
                        evaluation                                                 board
                                                                                 Yellow Belt Certification
     Basic Training    •Recommendation - 2 weeks/month; 5 Days/Week : 25
                                                                                  for ~500 employees in
     & Certification    Participants/Session)
                                                                                  India


3
                       •Define Annual Savings Target
                       •KRA's to employees for Lean/Six Sigma                    Goal setting
    Organizational     •Metrics capturing & Reporting
     Framework         •Core Six Sigma team identification to steer the          Employee
                        initiative throughout the organization                    Communication
                       •Define framework for Quality projects identification




                       A journey of a thousand miles begins with a single step
                                                                                                         5
4
    Lean, Six-sigma      • Green Belt Training                                     Green Belt Training
       Green Belt        • Training Duration - 4 days (Weekdays, or weekdays        Participant Certification
                          + weekends by continuous)                                Completed one Six
       Training &        • Recommendation - 2 trainings/month ;                     Sigma Project
      Certification       15 Participants/Session; ~115 participants               Green Belt Certification


5
                                                                                  Black Belt Participation
    Lean, Six-sigma      • Black Belt Training                                      Certification
       Black Belt        • Training Duration - 8 days (Wednesday to Saturday -    Completed One Six Sigma
                          2 weeks)                                                 Project
       Training &        • Recommendation - 1 training/month ; 10                 Mentored two Six Sigma
      Certification       Participants/Session; ~50 participants                    Projects
                                                                                  Black Belt Certification

6
                         • Yearly Target Plan for Lean Six Sigma
    Institutionalizing   • Lean Principles well deployed – 5S, Value Stream       Culture change
                          Mapping, Kaizen
     Lean Six Sigma      • Lean Six Sigma mentor and champions should be
                                                                                  Company-wide
         Culture                                                                   Implementation Plan
                          easily available during this phase to encourage and
                          guide new teams




                         A journey of a thousand miles begins with a single step
                                                                                                              6
Organizational   Frame
                                   work                                             Green Belt Certification
                                                       Yellow Belt Certification
                                                        Yellow Belt Certification
Define Lean Six Sigma      Yellow Belt Certification
       Strategy
                           Green Belt Certification     Green Belt Certification    Green Belt Certification




Green Belt Certification   Green Belt Certification         5S, Kaizen, Value
                                                                                    Black Belt Certification
                                                            Stream mapping
                                                                                       5S, Kaizen, Value
Green Belt Certification   Green Belt Certification                                    Stream mapping




                           Black Belt Certification     Black Belt Certification    Black Belt Certification
Black Belt Certification
                              5S, Kaizen, Value            5S, Kaizen, Value
   5S, Kaizen, Value          Stream mapping               Stream mapping              5S, Kaizen, Value
   Stream mapping                                                                      Stream mapping




                           A journey of a Thousand miles begins with a single step
                                                                                                               7
Target Audience
  Type        Pre-Requisite                         Training Approach              Certification Criteria
                                 (Minimum)

                                                    Instructor led Class
                                 All employees         Room Training
                                                                           1) Attending the YB Training
Yellow Belt       None         including support
                                                                           2) Scoring 75% + in the evaluation test
                                    function         Long term - Web
                                                      Based Training


                              Team Leaders, Group
                                                                         1) Attending the GB Training
                                Leaders & Project
                                                                         2) Scoring 75% + in the GB evaluation
               Yellow Belt         Managers         Instructor led Class
Green Belt                                                               test
                Certified                              Room Training
                                                                         3) 1 Green Belt project completion with
                               (25% of the total
                                                                         annual saving of $5,000.00 or above
                                  work force)


                                                                         1) Attending the BB Training
                                                                         2) Scoring 75%+ in the BB evaluation
                               Project Managers
                                                                         test
                Green Belt                          Instructor led Class
Black Belt                                                               3) 2 GB Projects completion with total
                 Certified     (10% of the total       Room Training
                                                                         annual savings of $10,000 or above
                                  work force)
                                                                         4) Mentoring of 2 GB projects along with
                                                                         their certification




                                A Journey of a Thousand miles begins with a single step
                                                                                                                8
Designing Six Sigma Framework
•Designing the Six Sigma Strategy and Road map aligned to Organization’s goals
 & objectives
•Goal setting for Six Sigma Strategy
•Lean Six Sigma Initiative branding
•Mechanism to Track & Report Benefits Realization

Training & Certification
•Designing the Training Calendar for Lean Six Sigma as per the Organization’s
 HR/Training guidelines
•Certification criteria that is aligned to Organization’s Six Sigma Strategy
•Evaluation Question Paper to include both theoretical and Scenario based
 questions

Consultation & Mentoring
•Conduct work shops, Brain storming sessions to identify opportunities for Lean &
 Six Sigma projects also best practice sharing
•Help the team with the DMAIC/DMADV documentation and tollgate approvals
•Mentoring 10 Green Belt Projects
•Tracking and Reporting Benefits



                 With Lean Six Sigma… Only results counts…
                                                                                    9
Focus on Preliminary requirements while
           embarking on Lean Six Sigma


             Imperative to adopt the phase wise
             roadmap for a systematic approach


                 Need to promote it as a way of life from
                             now onwards


Other early adopters of Six Sigma who achieved great success include Honeywell
International and General Electric.

By the late 1990s, about two-thirds of the Fortune 500 organizations had begun Six
Sigma initiatives with the aim of reducing costs and improving quality.


                    Let’s Begin The Journey Towards Operational
                    Excellence…                                                      10
LEAN Six Sigma - An Introduction

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LEAN Six Sigma - An Introduction

  • 1. o What is Lean Six Sigma… o Why Lean Six Sigma… o How we do… o When to do Journey Towards Operational Excellence….. 1
  • 2. Lean Six Sigma is a Business Management Strategy …  Seeks to identify and remove the causes of defects and errors  Uses a set of management methods, including statistical methods  Creates a high performing culture within the organization Aims To Deliver Breakthrough Performance In Business Or Operational Measures Like Customer Satisfaction Rating Score Cost of executing a business process transaction Billing and Cash Collection lead time Yield (Productivity) of service operations or production “When you are finished changing, you're finished.” Benjamin Franklin 2
  • 3. ...Features that clearly distinguish Lean Six Sigma from other quality methodology Six Sigma Lean is a Motorola has reported over rigorous, data-driven, result US$17 oriented approach to billion in process improvement. savings from It helps in improving Six Sigma as of 2006 quality, efficiency & speed in every aspect of business 1) Ability to distinguish the problems and symptoms 2) Structured approach to problem solving 3) Root cause analysis for permanent fixes 4) Leverage the tools, techniques and best practices for data analysis and solution 1) Able to achieve growth through increased productivity 2) Achieve great customer satisfaction 3) Improves employee engagement & satisfaction 4) Creates an overall high performing culture within the organization 5) Gives a competitive edge in the market place “It is not enough to do your best; you must know what to do, and then do your best “ - Deming Company Confidential 3
  • 4. Defining Road map Institutionalizing Yellow Belt Training & Lean Six Sigma Monitor Certification Culture Train Black Belt Organizational Training & Consult Framework Certification Green Belt Training & Certification Our objective is to create value proposition & business outcomes through six sigma consulting… 4
  • 5. 1 •Define Goals & objectives  Lean/Six Sigma •Discussions on current issues Program Rollout Define •Why Six Sigma ( benefits)  Employee Training plan Lean Six Sigma •Training & Certification criteria; Role definition  Six Sigma/Lean Strategy •Benefits Realization & Review Mechanism Training Calendar •Establish communication plan and channels for rollout  Employees/Stakeholder notification 2 Lean, Six-sigma •Six Sigma Awareness & LEAN  Lean/Six Sigma awareness across the Yellow Belt •Training duration - 1 day; 7 hours training & 1 hour evaluation board  Yellow Belt Certification Basic Training •Recommendation - 2 weeks/month; 5 Days/Week : 25 for ~500 employees in & Certification Participants/Session) India 3 •Define Annual Savings Target •KRA's to employees for Lean/Six Sigma  Goal setting Organizational •Metrics capturing & Reporting Framework •Core Six Sigma team identification to steer the  Employee initiative throughout the organization Communication •Define framework for Quality projects identification A journey of a thousand miles begins with a single step 5
  • 6. 4 Lean, Six-sigma • Green Belt Training  Green Belt Training Green Belt • Training Duration - 4 days (Weekdays, or weekdays Participant Certification + weekends by continuous)  Completed one Six Training & • Recommendation - 2 trainings/month ; Sigma Project Certification 15 Participants/Session; ~115 participants  Green Belt Certification 5  Black Belt Participation Lean, Six-sigma • Black Belt Training Certification Black Belt • Training Duration - 8 days (Wednesday to Saturday -  Completed One Six Sigma 2 weeks) Project Training & • Recommendation - 1 training/month ; 10  Mentored two Six Sigma Certification Participants/Session; ~50 participants Projects  Black Belt Certification 6 • Yearly Target Plan for Lean Six Sigma Institutionalizing • Lean Principles well deployed – 5S, Value Stream  Culture change Mapping, Kaizen Lean Six Sigma • Lean Six Sigma mentor and champions should be  Company-wide Culture Implementation Plan easily available during this phase to encourage and guide new teams A journey of a thousand miles begins with a single step 6
  • 7. Organizational Frame work Green Belt Certification Yellow Belt Certification Yellow Belt Certification Define Lean Six Sigma Yellow Belt Certification Strategy Green Belt Certification Green Belt Certification Green Belt Certification Green Belt Certification Green Belt Certification 5S, Kaizen, Value Black Belt Certification Stream mapping 5S, Kaizen, Value Green Belt Certification Green Belt Certification Stream mapping Black Belt Certification Black Belt Certification Black Belt Certification Black Belt Certification 5S, Kaizen, Value 5S, Kaizen, Value 5S, Kaizen, Value Stream mapping Stream mapping 5S, Kaizen, Value Stream mapping Stream mapping A journey of a Thousand miles begins with a single step 7
  • 8. Target Audience Type Pre-Requisite Training Approach Certification Criteria (Minimum) Instructor led Class All employees Room Training 1) Attending the YB Training Yellow Belt None including support 2) Scoring 75% + in the evaluation test function Long term - Web Based Training Team Leaders, Group 1) Attending the GB Training Leaders & Project 2) Scoring 75% + in the GB evaluation Yellow Belt Managers Instructor led Class Green Belt test Certified Room Training 3) 1 Green Belt project completion with (25% of the total annual saving of $5,000.00 or above work force) 1) Attending the BB Training 2) Scoring 75%+ in the BB evaluation Project Managers test Green Belt Instructor led Class Black Belt 3) 2 GB Projects completion with total Certified (10% of the total Room Training annual savings of $10,000 or above work force) 4) Mentoring of 2 GB projects along with their certification A Journey of a Thousand miles begins with a single step 8
  • 9. Designing Six Sigma Framework •Designing the Six Sigma Strategy and Road map aligned to Organization’s goals & objectives •Goal setting for Six Sigma Strategy •Lean Six Sigma Initiative branding •Mechanism to Track & Report Benefits Realization Training & Certification •Designing the Training Calendar for Lean Six Sigma as per the Organization’s HR/Training guidelines •Certification criteria that is aligned to Organization’s Six Sigma Strategy •Evaluation Question Paper to include both theoretical and Scenario based questions Consultation & Mentoring •Conduct work shops, Brain storming sessions to identify opportunities for Lean & Six Sigma projects also best practice sharing •Help the team with the DMAIC/DMADV documentation and tollgate approvals •Mentoring 10 Green Belt Projects •Tracking and Reporting Benefits With Lean Six Sigma… Only results counts… 9
  • 10. Focus on Preliminary requirements while embarking on Lean Six Sigma Imperative to adopt the phase wise roadmap for a systematic approach Need to promote it as a way of life from now onwards Other early adopters of Six Sigma who achieved great success include Honeywell International and General Electric. By the late 1990s, about two-thirds of the Fortune 500 organizations had begun Six Sigma initiatives with the aim of reducing costs and improving quality. Let’s Begin The Journey Towards Operational Excellence… 10