Upload
shariq-ali
View
236
Download
0
Embed Size (px)
Citation preview
7/30/2019 1.Introduction Sfd
1/90
Sixsigma-introduction/bnj/AVBG
INTRODUCTION TO
SIX SIGMA
7/30/2019 1.Introduction Sfd
2/90
Sixsigma-introduction/bnj/AVBG
What is Six Sigma?
7/30/2019 1.Introduction Sfd
3/90
Sixsigma-introduction/bnj/AVBG
Six Sigma is a philosophy;
one of making fewer and fewer mistakes in
everything we do - from the way we
manufacture products to the way we fill out apurchase order.
As we discover and eliminate harmful sources
of variation, our process capability improvesand the defects (mistakes) go away.
WHAT IS SIX SIGMA?
7/30/2019 1.Introduction Sfd
4/90
Sixsigma-introduction/bnj/AVBG
WHAT IS DEFECT?
1 2 3 4
CUSTOMERSProcess Steps
INPUTS
Business Organization
Products& Services
Payment5
Business Results:
Revenue, Profit, Cash Flow,
Shareholders
7/30/2019 1.Introduction Sfd
5/90
Sixsigma-introduction/bnj/AVBG
WHAT IS DEFECT?
Failure to meet the
Standard of Performance.
Output of process in Time Sequence Output of processes in Time sequence
Failure to challenge the
Standard of Performance.
Y Y
7/30/2019 1.Introduction Sfd
6/90
Sixsigma-introduction/bnj/AVBG
WHAT IS DEFECT?
Big Ys:Revenue (Y1)
Profit (Y2)
Cash Flow (Y3)
7/30/2019 1.Introduction Sfd
7/90
7/30/2019 1.Introduction Sfd
8/90
Sixsigma-introduction/bnj/AVBG
WHAT IS DEFECT?
Big Y vs Small Ys:
Profit (Y 2)
Cost per Unit
(Y 2.1)Realisation per
Unit (Y 2.2)
Fixed
Costs
(Y 2.1.1)
Variable
Costs
(Y 2.1.2)
Existing
Customers
(Y 2.2.1)
New
Customers
(Y 2.2.2)
7/30/2019 1.Introduction Sfd
9/90
Sixsigma-introduction/bnj/AVBG
WHAT IS DEFECT?
Big Yvs Small Ys:
Cash Flow (Y 3)
Inventory
(Y 3.1)
Payables
(Y 3.3)
Stores
(Y 3.1.1)
FGI
(Y 3.1.3)
Receivable
(Y 3.2)
WIP
(Y 3.1.2)
7/30/2019 1.Introduction Sfd
10/90
Sixsigma-introduction/bnj/AVBG
5004003002001000
400
350
300
Observation Number
Individu
alValue
Chart for OUTPUT/Hr.
1 1 1
1
1
1111111
1
1111
11
111
11
1
1
11111111
1
1
11111
11111
1
1
1
1
111111
11
11111
111
1111111 11111
11111111
1111
1
11111111
1
1
111
1
111111111
1
111
1
11111
11111
1
111111
1
111111 1
1
1 1 11
11
1111111
Mean=340.4
UCL=357.7
LCL=323.2
7/30/2019 1.Introduction Sfd
11/90
Sixsigma-introduction/bnj/AVBG
Six Sigma is a Statistical Measurement
Sigma Rating of a Process is measure of
Goodness of a process w.r.t. its ability to meet
the Standard of Performance.
Higher is the Sigma Level of a process, better
is its ability to meet the Standard of
Performance and hence fewer and fewer
defects .
WHAT IS SIX SIGMA?
7/30/2019 1.Introduction Sfd
12/90
Sixsigma-introduction/bnj/AVBG
SIGMA RATING AND LEVEL OF DEFECT
Sigma Rating Defect(ppm) Yield(%)1 690,000 30.92 308,537 69.2
3 66,807 93.2
4 6,210 99.4
5 233 99.98
6 3.4 99.9997
ppm: Parts per million
7/30/2019 1.Introduction Sfd
13/90
Sixsigma-introduction/bnj/AVBG
Six Sigma is a statistical measurement
The Sigma Rating allows us: To draw comparisons between similar or
dissimilar products, services and processes.
To see how far ahead or behind we are.
To set the target for Process improvement
To gauge our pace in the race for total customer
satisfaction.
WHAT IS SIX SIGMA?
7/30/2019 1.Introduction Sfd
14/90
7/30/2019 1.Introduction Sfd
15/90
Sixsigma-introduction/bnj/AVBG
Three Sigma would be equivalent to one misspelled
word per 15 pages of text.
Six Sigma would be equivalent to one misspelled
over 300,000 pages, quite a difference indeed.
Three Sigma versus Six Sigma
7/30/2019 1.Introduction Sfd
16/90
Sixsigma-introduction/bnj/AVBG
SHOULD ALL PROCESSES BE
AT SIX SIGMA?
The airline fatality rate is about 6.5
sigma, but airline baggage handling isabout 4 sigma
7/30/2019 1.Introduction Sfd
17/90
Sixsigma-introduction/bnj/AVBG
Six Sigma as a Business Strategy
WHAT IS SIX SIGMA?
Sigma Rating
Customer
Satisfaction
Costs
Customer Value
Shareholder Value
7/30/2019 1.Introduction Sfd
18/90
Sixsigma-introduction/bnj/AVBG
Basic Tenets of Six Sigma
Customer Orientation
Process OrientationSpeak with facts
7/30/2019 1.Introduction Sfd
19/90
Sixsigma-introduction/bnj/AVBG
NO COMPANY MAKES MONEY INSIDE
THE ORGANISATION
EVERYTHING DONE INSIDE THE COMPANY IS
COST
ONLY WHEN THE COMPANY GOES OUTSIDE ITHAS AN OPPOURTUNITY TO MAKE MONEY
SO, WHAT IS THEREAL PURPOSEOF BUSINESS ?
Customer Orientation
7/30/2019 1.Introduction Sfd
20/90
Sixsigma-introduction/bnj/AVBG
THE REAL PURPOSE OF BUSINESS IS:
TO FIND CUSTOMERS
SUCCESS IN FINDING THEM
AND SATISFYING THEM
IS MEASURED BY THE
PROFITS
WE MAKE
Customer Orientation
7/30/2019 1.Introduction Sfd
21/90
Sixsigma-introduction/bnj/AVBG
The best six sigma project begin not inside thebusiness but outside it, focused on answeringthe question - how can we make the customer
more competitive? What is critical to thecustomers success?..
One thing we have discovered with certainty isthat anything we do that makes the customermore successful inevitably results in a financialreturn to us.
Jack Welch
Customer Orientation
7/30/2019 1.Introduction Sfd
22/90
Sixsigma-introduction/bnj/AVBG
C
U
ST
O
M
ER
MARKETING ENGINEERING
PROCUREMENT
MANUFACTURINGDESPATCH
Every Organization is like a Relay Race
Customer Orientation
7/30/2019 1.Introduction Sfd
23/90
Sixsigma-introduction/bnj/AVBG
Focusing on the Inside will hurt ...
Customer Orientation
7/30/2019 1.Introduction Sfd
24/90
Sixsigma-introduction/bnj/AVBG
COMPETITIORS
Capital
Market
LaborMarket
Suppliers
ENVIRONMENTAL INFLUENCES (Government, Economy, Culture)
Process orientation
C
U
ST
O
M
E
R
S
Business OrganizationAcquire
Order
Execute
Order
Deliver
Order
Support Processes:
Leadership
HR
Finance, etc.
7/30/2019 1.Introduction Sfd
25/90
Sixsigma-introduction/bnj/AVBG
Enabler
WorldClass
Contenders
Wont go the
Distance
Punch Bag Promising
60%
0%60% 100%
80%
80% 100%
Process orientation
7/30/2019 1.Introduction Sfd
26/90
Sixsigma-introduction/bnj/AVBG
Functional Silos
QCD QCD QCD QCD
Marketing Engineering Production Dispatch
Process orientation
7/30/2019 1.Introduction Sfd
27/90
Sixsigma-introduction/bnj/AVBG
Functional Silos
QCD QCD QCD QCD
Marketing Engineering Production Dispatch
Customer
Process orientation
7/30/2019 1.Introduction Sfd
28/90
Sixsigma-introduction/bnj/AVBG
INDENTOR
/US
ER
PURC
HASE
STO
RES
PROCUREMENT PROCESS
RightQuality
Quantity
Price
Time
FUNCTIONAL vs PROCESSTARGET
Process orientation
7/30/2019 1.Introduction Sfd
29/90
Sixsigma-introduction/bnj/AVBG
Process Measures
Marketing Engineering Procurement Manufacturing Sales
Customer
CustomerM1-E= EXT/CR MEASURESM1-I = INT/BUSINESS MEASURESM2 = SUB-PROCESS MEASURESM3 = KEY PROCESS STEP MEASURES
M1-I
M1-E
M2
M2
M3 M3M2
Process orientation
7/30/2019 1.Introduction Sfd
30/90
S k ith F t
7/30/2019 1.Introduction Sfd
31/90
Sixsigma-introduction/bnj/AVBG
IN GOD WE BELIEVE,
FOR EVERYTHING ELSE
BRING DATA
Speak with Facts
S k ith F t
7/30/2019 1.Introduction Sfd
32/90
Sixsigma-introduction/bnj/AVBG
DATA COLLECTION:
What?
How?
How much?
Depends on OBJECTIVE of Data?
Speak with Facts
S k ith F t
7/30/2019 1.Introduction Sfd
33/90
Sixsigma-introduction/bnj/AVBG
DATA COLLECTION: OBJECTIVE?
Know current Status
Investigate / Experiment
Control for future
Speak with Facts
7/30/2019 1.Introduction Sfd
34/90
7/30/2019 1.Introduction Sfd
35/90
Sixsigma-introduction/bnj/AVBG
What is Six Sigma?Proven benefits of Six Sigma system are diverse,
Including:
Cost reduction
Productivity improvement
Market share growth
Customer retention
Cycle -time reduction
Defect reduction
Culture change, etc.
Genius of the And
7/30/2019 1.Introduction Sfd
36/90
7/30/2019 1.Introduction Sfd
37/90
7/30/2019 1.Introduction Sfd
38/90
7/30/2019 1.Introduction Sfd
39/90
Sixsigma-introduction/bnj/AVBG
YearRevenue
($B)
Invested
($B)
%RevenueInvested
Savings
($B)
%RevenueSavings
1996 79.2 0.2 0.3 0.2 0.2
1997 90.8 0.4 0.4 1 1.1
1998 100.5 0.5 0.4 1.3 1.2
1999 111.6 0.6 0.5 2 1.8
Six SigmaCosts and Savings at GE
7/30/2019 1.Introduction Sfd
40/90
Sixsigma-introduction/bnj/AVBG
Allied Signal
Allied Signal, which was on the verge of bankruptcy was made
profitable by CEO Larry Bossidy through Six Sigma.The company implemented Six Sigma program in 1994. The
cumulative impact on the savings in the direct costs during this
period (till 1999) was more than US$ 2 billion
Asea Brown Boveri
ABB, after application of Six Sigma has reduced
equipment error by 83%. The company also made drasticimprovements in material handling resulting in an annual
estimated cost savings of US $775000.
7/30/2019 1.Introduction Sfd
41/90
Sixsigma-introduction/bnj/AVBG
Johnson & Johnson
Reported in its respective annual reports that Six Sigmasaved $200 million in 1999, $350 million in 2000, and $500
million in 2002.
Ford Motor Company
On its website reported that its customer driven 6-sigma
initiative contributed more than $52 million to the bottom
line in 2000, its inaugural year , with the expectation of
delivering another $200 million by the time the 2002annual report was published.
7/30/2019 1.Introduction Sfd
42/90
Sixsigma-introduction/bnj/AVBG
Honeywell
Honeywell states on its website thatSix Sigma projects have saved $500Million in 1998, $500 Million in 1999
and $700 Million in 2000.
7/30/2019 1.Introduction Sfd
43/90
7/30/2019 1.Introduction Sfd
44/90
Sixsigma-introduction/bnj/AVBG
PROJECT BY PROJECT APPROACH
A PROJECT IS A PROBLEM CHOSEN FOR
SOLUTION.
ALL IMPROVEMENT IS MADE PROJECT BY
PROJECT AND IN NO OTHER WAY.
WHATEVER IS NOT A PROJECT WILL NOT
GET IMPROVED.
JM JURAN
METHODOLOGY
7/30/2019 1.Introduction Sfd
45/90
Sixsigma-introduction/bnj/AVBG
METHODOLOGY
Identify Six Sigma
Projects
Carryout Six SigmaProjects
Integration with Business
Planning Process
Institutionalization
Management Team Buy-in
Creating Organization
for Six Sigma
Training People on SixSigma
7/30/2019 1.Introduction Sfd
46/90
Sixsigma-introduction/bnj/AVBG
ORGANIZATION
FOR SIX SIGMA
7/30/2019 1.Introduction Sfd
47/90
Sixsigma-introduction/bnj/AVBG
Management Team
The CEO should be the main driver of the Six Sigma program.
Under him departmental / functional heads have to take
charge in implementing the program. They are called Six
Sigma Champions
The Champions must have knowledge on applications and
interpretation of statistical tools.
7/30/2019 1.Introduction Sfd
48/90
Sixsigma-introduction/bnj/AVBG
Six Sigma Black Beltworks with:
The resolve toattain
greater heights
7/30/2019 1.Introduction Sfd
49/90
Sixsigma-introduction/bnj/AVBG
Six Sigma Black belts believe that
Standardsexist to be
superseded
7/30/2019 1.Introduction Sfd
50/90
SIX SIGMA ORGANIZATION
7/30/2019 1.Introduction Sfd
51/90
Sixsigma-introduction/bnj/AVBG
SIX SIGMA ORGANIZATION
Six Sigma project Teams Owned byChampions and led by Black Belts
Responsibilities of CHAMPION as Sponsor
7/30/2019 1.Introduction Sfd
52/90
Sixsigma-introduction/bnj/AVBG
of Six Sigma project:
Ensuring that resources are available for training and projects
Participating in project reviewParticipating in Project selection and scoping
Providing Strategic direction to the project team
Staying informed about the teams progress
Helping the Black Belt overcome road-blocks
Keeping the team focused on the desired result
Redirecting the teams activities, if unanticipated events occur
Keeping the Management Team informed
Being accountable for the results.
7/30/2019 1.Introduction Sfd
53/90
Sixsigma-introduction/bnj/AVBG
Understandsthe BigPicture of the business.
Understands clearly where Cost is incurred and where
Value is added.
An expert in application ofprocess improvement tools.
Capable ofconsulting, mentoring and coaching.
Drives change by challenging conventional wisdom.
CHARACTERISTICS OF SIX SIGMABLACK BELT
7/30/2019 1.Introduction Sfd
54/90
Sixsigma-introduction/bnj/AVBG
ROLES OF A SIX SIGMA BLACK BELTMentoring:Cultivate a network of local Six Sigma individuals
at the local organization or site.
Teaching: Provide formal training of local personnel in newstrategies and tools
Coaching:Provide a one-on-one support to local personnel
Transferring:Pass on new strategies and tools in the form of
training, workshops, case studies, local symposia, etc. Discovering:Finding application opportunities for Six Sigma
strategies and tools, both internal and external (e.g., suppliersand customers)
Identifying: Surfacing business opportunities throughpartnerships with other organizations
Influencing:Selling the organization on the use of Six Sigmastrategies and tools
7/30/2019 1.Introduction Sfd
55/90
Sixsigma-introduction/bnj/AVBG
Master Black Belts - Responsibilities
The Master Black Belts should take the mainresponsibility of implementing Six Sigmaprogram.
They must assist the organization in identifyingSix Sigma projects and also develop and trainBlack Belts under them.
7/30/2019 1.Introduction Sfd
56/90
Sixsigma-introduction/bnj/AVBG
TRAINING PEOPLE
FOR SIX SIGMA
WHAT MADE SIX SIGMA
7/30/2019 1.Introduction Sfd
57/90
Sixsigma-introduction/bnj/AVBG
WHAT MADE SIX SIGMA
SUCCESSFUL AT GE
Quotes from GE Annual Report 1997
GE had a huge advantage that accelerated our quality
efforts: we had a Company that was open to change,
hungry to learn and anxious to move quickly on a good
idea.
Six Sigma is quickly becoming part of the genetic code of
our future leadership
7/30/2019 1.Introduction Sfd
58/90
Sixsigma-introduction/bnj/AVBG
CHAMPION CERTIFICATION
Successful completion of Class-room training
+
Successful completion of at least One High
impact Six Sigma Project in his work-area.
7/30/2019 1.Introduction Sfd
59/90
Sixsigma-introduction/bnj/AVBG
BLACK BELT CERTIFICATION
Class Room Training ( Phase 1)6days
Carry out Six Sigma Project12 weeks (app.)
Class Room Training ( Phase 2)6daysContinue Six Sigma Project12 weeks (app)
Evaluation and Certification
7/30/2019 1.Introduction Sfd
60/90
Sixsigma-introduction/bnj/AVBG
Attendance during Class room training Phase 1 and 2
Faculty assessment during the training
Obtaining Qualifying Marks in the Tests during training
Successful completion of the Project
Evaluation of learning from project by expert
-
EVALUATION CRITERIA
7/30/2019 1.Introduction Sfd
61/90
Sixsigma-introduction/bnj/AVBG
How to identify Six
Sigma Projects?
7/30/2019 1.Introduction Sfd
62/90
Sixsigma-introduction/bnj/AVBG
IDENTIFY SIX SIGMA
PROJECTS
Six Sigma Project Identification Process depends
on the Objective of implementing Six Sigma:
Strategic Improvement
Problem Solving.
IDENTIFY SIX SIGMA PROJECTS
7/30/2019 1.Introduction Sfd
63/90
Sixsigma-introduction/bnj/AVBG
IDENTIFY SIX SIGMA PROJECTS
Problem Solving:
Fixes specific areas of high cost, rework,delays, Customer Complaints.
With an urgency of results driving nearly everysix sigma start-up, most organizations choose
to jump on this objective.
Only problem solving can not bring highimpact on Business as there is always a dearthof problem after some time.
IDENTIFY SIX SIGMA PROJECTS
7/30/2019 1.Introduction Sfd
64/90
Sixsigma-introduction/bnj/AVBG
IDENTIFY SIX SIGMA PROJECTS
Strategic ImprovementTargets key strategic or operational
weaknesses or opportunities.Strategic improvement effort lead to fewer key
improvement projects with each project
creating high business impact.
7/30/2019 1.Introduction Sfd
65/90
Sixsigma-introduction/bnj/AVBG
Existing New
Customers
Product
Existing
New
Problem
Solving
VOC
Product
modifications
Marketing
New applications
R&D
Time to
market
Strategic Projects
QFD FOR PROJECT IDENTIFICATION
7/30/2019 1.Introduction Sfd
66/90
Sixsigma-introduction/bnj/AVBG
WHAT
(Voice ofCustomer)
HOW(Product/ Service
Specification)
RELATIONSHIPMATRIX
Ranked Hows
WHAT
(Ranked Product/
service Specification)
HOW(Process Stages)
RELATIONSHIP
MATRIX
Ranked Hows
(Voice of Customers)
QFD FOR PROJECT IDENTIFICATION
7/30/2019 1.Introduction Sfd
67/90
Sixsigma-introduction/bnj/AVBG
WHAT
(Voice of
Shareholders)
HOW
(Process Stages)
RELATIONSHIP
MATRIX
Ranked Hows
(Voice of Shareholders)
SELECTING HIGH IMPACT
7/30/2019 1.Introduction Sfd
68/90
Sixsigma-introduction/bnj/AVBG
SELECTING HIGH IMPACT
PROJECT
LOW HIGH
CUSTOMER IMPACT
Priority-1
Priority-2
Priority-3
Priority-4
7/30/2019 1.Introduction Sfd
69/90
7/30/2019 1.Introduction Sfd
70/90
Sixsigma-introduction/bnj/AVBG
CATEGORIES OF CUSTOMERS
1 WEAVING USE 40%
2 KNITTING USE 30%
3 INDUSTRIAL END USE 30%
RELATING CUSTOMER REQUIREMENTS TO
7/30/2019 1.Introduction Sfd
71/90
Sixsigma-introduction/bnj/AVBG
RELATING CUSTOMER REQUIREMENTS TO
INTERNAL MEASURES
Sr.no Customer
Requirements
Quality parameters / Measures
Count
Variation
Uster (%) Yarn
Strength
Elongation IPI Yarn
Hairiness
Length in
Cone
Whitenes Knot/Splic T.P.I.
1 Uniform Fabric 8 9 3 3 3 3 3 3
2 Fabric Strength 6 3 9 3 1 3
3 Productivity 5 9 3 3 3 3
4 Less Wastage 5 3 9
WEIGHTED RATING 90 24 114 15 24 57 60 24 45 42
Degree of
importance
(Scale 1 to 9)
Very important: 9
Somewhat important: 3
Low effect: 1
7/30/2019 1.Introduction Sfd
72/90
Sixsigma-introduction/bnj/AVBG
PROCESSES & THEIR EFFECTSr.no. Quality Measures Rating Sub processes & their effect on quality measures
Fibre BlowRoom
Carding Drawing Simples RingSpinning
Winding ParallelWinding
Doubling&
Twisting
FinalInspectio
n &
Packing
1 Count Variation 90 1 3 9 3 9
2 Uster 24 1 3 3 9
3 Yarn Strength 114 9 3
4 Elongation 15 9 3 3
5 IPI 24 9 3 3
6 Hairiness 57 9 3 3
7 Length in cones 60 3 3 9 9
8 Whiteness 24 9 3
9 Knot /Splice 45 9 3 9
10 T.P.I. 42 3 9
PROCESS RATING 1,377 162 1,062 1,062 342 2,178 1,188 675 999
PRESENT SIGMA LEVELStage Sub process Checks Specification Limits Observed Performance for Oct'01 Cp Cpk Sigma
7/30/2019 1.Introduction Sfd
73/90
Sixsigma-introduction/bnj/AVBG
g
no.
p p p p g
Level
USL LSL Avg. S.D. Max Min
1 Fibre Moisture (%)
2 Blow Room Blend Variation 67.00 66.00 66.40 0.067 66.68 66.24 2.64 2.14 6.42
3 Carding Wrapping Cv
Uster (%)
4 Drawing Wrapping Cv 0.18 0.12 0.15 0.014 0.18 0.12 0.73 0.71 2.13Uster (%) 2.30 1.90 2.13 0.043 2.27 2.06 1.62 1.40 4.20
5 Simplex Wrapping Cv
Uster (%) 3.50 2.90 3.22 0.091 3.44 3.04 1.03 0.96 2.88
6 Ring Spinning Count Cv 1.60 1.00 1.35 0.092 1.56 1.26 1.02 0.98 2.94
Uster (%) 9.70 8.50 9.13 0.174 9.74 8.65 1.15 1.10 3.30
I.P.I.
Hairiness 4.50 3.50 3.97 0.216 4.50 3.53 0.77 0.73 2.19
Strength 19.00 17.00 18.15 0.601 19.31 17.11 0.83 0.75 2.25
Elongation 14.00 11.00 11.93 0.677 13.67 11.04 0.74 0.46 1.38
7 Winding I.P.I.
Uster (%) 10.50 9.00 9.64 0.205 10.05 9.20 1.22 1.04 3.12
Hairiness 6.00 4.40 5.26 0.302 5.80 4.74 0.88 0.82 2.46
Yarn Strength 18.50 15.50 17.70 0.613 18.30 16.31 0.82 0.67 2.01
Length in cone
Elongation 12.50 10.50 11.68 0.590 12.64 10.40 0.56 0.46 1.38
8 Parallel winding Knot/Splice Str.
Length
9 Doubling &
Twisting Knot StrengthHairiness 8.50 7.10 7.76 0.280 8.35 7.13 0.83 0.79 2.37
TPI
Strength 19.50 16.50 18.17 0.560 19.10 17.14 0.89 0.79 2.37
Elongation 15.00 12.50 13.77 0.484 14.82 12.90 0.86 0.85 2.55
Uster (%) 8.30 7.30 7.82 0.176 8.18 7.53 0.98 0.94 2.82
10 Final Inspection Visual
11 Packing Wt. Of carton
Average: 2.75
Project selectionHi h i t d L Si L l h t i ti
7/30/2019 1.Introduction Sfd
74/90
Sixsigma-introduction/bnj/AVBG
Stage no. Importance Sub process Checks Sigma
Level
1 1377 Fibre Moisture (%)
2 162 Blow Room Blend Variation 6.423 1062 Carding Wrapping Cv
Uster (%)
4 1062 Drawing Wrapping Cv 2.13
Uster (%) 4.20
5 342 Simplex Wrapping Cv
Uster (%) 2.88
6 2178 Ring Spinning Count Cv 2.94
Uster (%) 3.30
I.P.I.
Hairiness 2.19Strength 2.25
Elongation 1.38
7 1188 Winding I.P.I.
Uster (%) 3.12
Hairiness 2.46
Yarn Strength 2.01
Length in cone
Elongation 1.38
8 675 Parallel winding Knot/Splice Str.
Length9 999 Doubling & Twisting Knot Strength
Hairiness 2.37
TPI
Strength 2.37
Elongation 2.55
Uster (%) 2.82
High importance and Low Sigma Level characteristics are
selected as Improvement projects
7/30/2019 1.Introduction Sfd
75/90
Sixsigma-introduction/bnj/AVBG
Customer Voice
Priority
BundleTenacity
Condition
Tenacity
Condition
Elongation
LongFibre'S'
LongFibre(M+P)
Spg.Faults-Free
Bales(G+R)
Denier
Whiteness
Brightness
OPU
Nepspergram
ShortFibre
.
Moist.Range(11-
13OTIF
Timetakento
resolvecomplaint
O O O
CSP 10 9 9 3 1 1 1 3 1 1 3 3 1 3 - -
Shade Variation 9 1 1 1 1 1 1 1 9 9 1 1 1 3 3 3
Imperfection 8 3 3 3 3 3 3 3 1 1 3 9 3 3 - -
Yield 7 3 3 3 3 3 3 1 1 1 3 3 3 9 - -
Delivery 8 - - - - - - - - - - - - - 9 3
After Sales service 9 - - - - - - - - - - - - - 3 9
Total - 144 144 84 64 64 64 70 106 106 84 132 64 144 126 132
PROJECT IDENTIFICATION FROM VOICE OF CUSTOMER
Product
Specification
7/30/2019 1.Introduction Sfd
76/90
Sixsigma-introduction/bnj/AVBG
PROCESSES /
PRODUCT
SPECIFICATIONPRIORITY
Order
Processing
RM
procurement
Viscose
Preparation
CS2/Acid
Preparation
Spinning
After
Treatment
Drying
Baling&
packing
Recovery
Steam&
power
Storage&
Despatch
ETP&WTP
Invoice&
Accounting
Maintenance
Storage&
issue
Skill
1 Bundle Tenacity 1449 9 9
2 Condition tenacity 144
9 9 93 % Prodn. In Moist.
Range (11-13)
144
9 3
4 Time taken to
resolve complaint
132
3 3
5 NEPS per gram 1323 3
2592 2592 396 1692 2592 432 396 396
PRIORITISATION INDEX FOR SIX SIGMA PROJECT
7/30/2019 1.Introduction Sfd
77/90
Sixsigma-introduction/bnj/AVBG
MAPING THE
VOICE OFSHAREHOLDER
7/30/2019 1.Introduction Sfd
78/90
Sixsigma-introduction/bnj/AVBG
VOICE OF SHAREHOLDER Priority
Raw
Materials
Stores
Items
Raw
Materials
Stores
ItemsMachine
Man
Power
1 Raw material Consumptio 10 9 9 9 1 1 1 1 1
2 Steam Consumption 10 9 3 3 1 1 1 1 1
3 Power Consumption 10 9 3 3 1 1 1 1 1
4 Stores Consumption 8 1 1 1 9 1 3 3 1
5 Repairs to Machinery 6 1 3 1 3 1 3 3 1
6 Over Time 3 1 1 1 1 1 1 1 1
7 Employee Cost 3 1 1 1 1 1 1 1 9
8 Admn. Expenses 1 1 1 1 1 1 1 1 1
9 Selling Expenses 1 1 1 1 1 1 1 1 110 Interest 3 1 1 1 1 3 1 1 1
11 Depriciation 1 1 1 1 1 1 1 1 1
RELATIVE IMPORTANCE 296 188 176 132 62 84 84 80
Improvement in
Consumption
Ratios
Reduction in
Purchase Cost
Increase in
Productivity
PRIORITISATION INDEX FOR SIX SIGMA PROJECT
Reduction
in
Equipment
Down time
Reductio
n in
Working
Capital
7/30/2019 1.Introduction Sfd
79/90
Sixsigma-introduction/bnj/AVBG
PROCESSES /
PRODUCT
SPECIFICATIONPRIORITY
Order
Processing&
Prodn.planning
RM
procurement
Viscose
Preparation
CS2/Acid
Preparation
Spinning
AfterTreatment
Drying
Baling&
packing
Recovery
Steam
&power
Generation
Storage&
Despatch
ETP&WTP
Invoice&
Accounting
Maintenance
Storage&issue
Skill
Information
System
1 Reduction in RM consumption Ratios
CS Lye 10 9 1 3
Steam 10 3 1 9 1 9 9Power 10 9 9 9 9 9 1 9
Coal 10 92 Reduction in Purchase cost of RM
CS Lye 5 9
Sulphur 5 3
Charcoal 5 33 Reduction in Working Capital
Steam Coal 3 9
Stores SparesInventory (FM)
3 9
RM Inventory 3 3
75 210 100 190 100 180 10 210 90 63
G R A S I M
GRASILENE DIVISION : HARIHAR
PRIORITISATION INDEX FOR SIX SIGMA PROJECT
SIX SIGMA PROJECT - STEPS
7/30/2019 1.Introduction Sfd
80/90
Sixsigma-introduction/bnj/AVBG
SIX SIGMA PROJECT - STEPS
There are 5 fundamental steps involved inapplying the breakthrough strategy for achieving
Six Sigma.
Define
Measure
Analyze
ImproveControl
DMAIC
7/30/2019 1.Introduction Sfd
81/90
Sixsigma-introduction/bnj/AVBG
Develop Business case and Team charter
Map the Current Process
Listen to the Voice of Customer
Define the Scope and Purpose
Define the boundaries
Expected resource needs
Project Timeline
DEFINE
7/30/2019 1.Introduction Sfd
82/90
Sixsigma-introduction/bnj/AVBG
Collect baseline data that pinpoints problem location and
occurrence
Develop a sampling strategy
Validate your measurement system
Determine Process Capability and Sigma Level
Learn concepts and tools needed to collect reliable and
accurate data A focused problem statement
MEASURE
ANALYZE
7/30/2019 1.Introduction Sfd
83/90
Sixsigma-introduction/bnj/AVBG
Process door Vs Data door
Identify potential causes ( Y= f (X1, X2, X3, Xn))
Create detailed process map and do value-added flow
analysis
Find, change in which Xs affect Y and in what manner,
using Statistical Techniques.
Ultimately find which Xs are critical to move the Y in the
desired direction and at what level those Xs are to be
maintained
ANALYZE
IMPROVE
7/30/2019 1.Introduction Sfd
84/90
Sixsigma-introduction/bnj/AVBG
Evolve an effective solution that addresses the root cause ofthe problem.
Evolve Should Process and its potential impact ( cost-
benefit analysis)
Assess risks and conduct Pilot Implementation
Routine implementation plan including budget, time line
and responsibilities.
IMPROVE
CONTROL
7/30/2019 1.Introduction Sfd
85/90
Sixsigma-introduction/bnj/AVBG
Develop Control plans and Control Charts to ensure thatgains are maintained.
Routine Implementation of Control Plan.
Standardize and Document effective methods
Evaluating Results, Summarize key learning's
Conduct revalidation when changes occurs in the Process /Product.
CONTROL
Integration with Business planning
7/30/2019 1.Introduction Sfd
86/90
Sixsigma-introduction/bnj/AVBG
Perspective Financials :
What do share holders expect and what objectives on thefinancial perspective does this imply?
Objectives
Perspective Customer / Markets: Which objectives have to be set in order to satisfy our
customers and to achieve the financial targets?
Objectives
Perspecitve Internal Processes: Which objectives have to be set regarding our processes
in order to fulfill the customer expectations in light of the
market conditions?
Objectives
Perspective Learning and Growth: Which objectives have to be set in order to develop crucialknowledge base, employees skills and future technologies?
Objectives
Integration with Business planning
Identify Six Sigma Project during Business Planning
Ca se and Effect Relationships
7/30/2019 1.Introduction Sfd
87/90
Sixsigma-introduction/bnj/AVBG
Financial
Market
share
On-timeDelivery
Customer
Loyalty
ProcessCycle Time
ProcessQuality
EmployeeSkills
Process
Customer
Learning &Growth
Cause-and-Effect Relationships
From: R.S. Kaplan and D. Norton
7/30/2019 1.Introduction Sfd
88/90
For the successful implementation of a strategy
7/30/2019 1.Introduction Sfd
89/90
12/20/2012 89
source: Motorola University (adapted by Horvth)
goals
abilities action plan resources incentives
goals
goals
goals
goals
abilities
abilities
abilities
abilities
action plan
action plan
action plan
action plan
resources
resources
resources
resources
incentives
incentives
incentives
incentives
+
+
+
+
+
+ + +
+
+
+
+
+ + +
+
+
+
+
=
=
=
=
=
=
confusion
fear
failing launch
frustration
little change
chaos
goals abilities action plan resources incentives+ + + + = intendedchange
information+
+
+
+
+
information
information
information
information
+ information
p gy
PEOPLE CAN BE DIVIDEDINTO THREE CATEGORIES
7/30/2019 1.Introduction Sfd
90/90
INTO THREE CATEGORIES
THOSE WHO WONDER
WHAT HAPPENED
THOSE WHO MAKE
THINGS HAPPEN
THOSE WHO WATCH
THINGS HAPPEN
J
K
L