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KPMG 6Sigma
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Draft Approach for Lean Six Sigma Green Belt Competency Development Program atIndian Institute of Management,Ranchi
29th June, 2015
Setting the ContextEstablishing the need for Six-Sigma Programs in organizations
3 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.
Six Sigma Drivers and LeversHow do we answer the key questions?
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Target Customer SegmentsVoice of customer
Analyst views
Purpose, Vision, Values, Goals
Input from business development
Competitive environment
Brand study
Financial Benefits
Revenue GrowthMargin Enhancement
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Service Benchmark
Quantitative Insight
Change management Strategy
Process Capability
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Quantified performance measurement
Growth Opportunity & career Progression
Compelling Purpose, Vision and Goal
4 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.
Six Sigma DriversHow do we answer the key questions?
Six Sigma is a set of strategies, techniques, and tools for process improvement. It was developed by Motorola in 1981.Six Sigma is a management methodology meant for driving process improvements in the delivery of goods andservices. It provides businesses with the tools to improve the capability of their business processes. The increase inperformance and decrease in process variation leads to defect reduction and vast improvement in profits, employeemorale and quality of product.
Six Sigma certification is similar to other professional courses in that after having cleared specified guidelines andfollowed the required procedure, individuals are certified as capable of employing the gained knowledge in theirrespective field. There are several stages of the program and with each qualifying level, certain tests that have to becleared. There are various belts such as green belt, black belt and master black belt awarded to professionals whocomplete corresponding stages of the course.
KPMG in India has developed a balanced program, specific to the needs of professionals, that allows yourtransformation into an effective change agent, who can, using the Six Sigma framework bring about significantimprovements in the organizations performance. Six Sigma Green Belt Course for Business Excellence is a four-daycomprehensive session to provide a firsthand experience of the nuances of Six Sigma. The training program wouldrevolve around the key concepts, the process of implementation and the specific challenges. The program also teachesthe basic statistical tools and techniques used in Six Sigma. The four days of Green Belt training will be conducted onthe various phases of DMAIC model to enable the Green Belts to work in terms of methodology, tools & techniques.
Six Sigma is an Industry Independent methodology and has been successfully applied across: Manufacturing Industry including Automotive, Aero Space, Health Equipment, FMCG, Electronic Goods, Continuous
Process Industry, Textiles etc. Service Industry including Telecom, Banking and Financial Services, Health Care, Insurance, Hotels, IT, ITES, KPOs,
Airlines, Cargo Movement, Support Services, HR Services, Marketing Services etc. R&D organizations or in R&D functions of various organizations
5 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.
Six Sigma: Domain wide Applications
Human Resource FinanceMarketing
OperationsInformationTechnology Logistics
Improve on-time delivery of products to customers
Improve on-time delivery of goods to our facility from vendors
Improve documentation accuracy Reduce line downtime due to
shipping/receiving Improve inventory control/rotation Improve inspection processes Reduce the space occupied by the
inventory
Increasing the effectiveness of the process
Optimizing the Sales cycle Improving the cost utilization Procurement time reduction and
optimization Reducing the defects in the process
flow Reduction in inventory system Waste reduction in internal
processes
Increasing customer engagement Reducing the overall Software
development times Improving the estimation process to
reduce time and cost overruns Improving the requirements
gathering process to reduce rework Reducing complaints resolution time Creating systems to detect defects
early in the process
Increasing customer engagement Reducing the overall Software
development times Improving the estimation process to
reduce time and cost overruns Improving the requirements
gathering process to reduce rework Reducing complaints resolution time Creating systems to detect defects
early in the process
Reduction in iteration rate of the employees
Training need assessment Improving the skill matrix for
employees Reduction in hiring time and
optimizing productive time Leave management system
optimization Optimum workforce management Reducing Mind to market cycle time
Turnaround time reduction of the customers
Error proofing of the system Optimizing product
disbursement time Reducing the Working Capital
and Financial requirements Developing new financial
products Optimizing procure to cash
cycle
6 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.
Six Sigma: Major Industry wide Applications
IT ServicesCreating systems to detect defects early in the
process (to reduce high costs associated with defects identified later)
Reducing appraisal cost per defect by phase and appraisal type (by project and in total)
Reducing reworkImproving the requirements gathering process
to reduce rework Reducing complaints resolution time
BankingReducing the Working Capital and
Financial requirementsDeveloping new financial productsOptimizing procure to cash cycleTurnaround time reduction of the
customersIncreasing sales productivity
FMCG Improving overall Yield of each shift Reduce scrap or spilled materials Reduce the Process failures or breakdowns Increase Plant capacity utilization Optimizing the Sales cycle Procurement time reduction and
optimization Reducing the defects in the process flow Reduction in inventory system
RetailEliminating manufacturing errors/defectsImproving first sample approval percentages
while working with buyersImproving buyer satisfaction levels Increasing repeat businessImproving supplier evaluation processesImproving processes at the source to reduce
rejections at later stagesReducing costs and delays
ManufacturingReduce Manufacturing cycle timeImprove Customer Service performance scoresReduce or optimize inventory levelsReduce cost of poor quality & warranty costReduce rejections due to design errorsImprove parts design process to meet
specificationsImprove parts reliability by identifying &
optimizing critical factors that ensure reliability
R&D/TechnologyReducing rework through synergy between R&D
and the customer facing staffImproving the overall performance & qualityMinimizing product failures by ensuring robust
designs and savings on warranty costImproving quality of research process &
experiments by providing mass education in Experimental design
Improving quality of design reviews
Course OverviewScope of the engagement
8 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.
Six-Sigma Green Belt Course - Overview
Six Sigma Green Belt Course for Business Excellence is a four-day comprehensive session to provide a first hand experience of the nuances of Six Sigma.
The workshop would revolve around the key concepts, the process of implementation and the specific challenges. The program also teaches the basic statistical tools and techniques used in Six Sigma.
Green Belts are an integral part of the Six Sigma methodology requiring sufficient training to support Six Sigma implementation. They are also qualified to lead certain Six Sigma improvement projects.
The four days of Green Belt training will be conducted on the various phases of DMAIC model to enable the Green Belts to work in terms of methodology, tools & techniques.
9 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.
Course Contents
DefineDefineCustomer Expectations of the process?
Understand Six Sigma Project definition and Charter High level Process Mapping COPIS
MeasureMeasureWhat is the frequency of defects?
Critical to Quality (CTQ) Characteristics Learning and usage of tools like FMEA, Cause and Effect diagram, Pareto and detailed process mapping
Performance standards MSA - Gage R&R, Attribute Agreement Analysis
AnalyzeWhy, Where & When do defects occur?
Graphical Analysis Process Capability Cp, Cpk, Zst and Zlt Identify variation sources Hypothesis testing ANOVA, Chi Square, 1-sample t, 2-sample t, 1-proportion, 2-
proportion, Regression Analysis
ImproveHow can we fix the Process?
Brainstorming techniques and TRIZ Solution Selection, error proofing - FMEA Pilot Improvement plans Deployment Cost Benefit Analysis
ControlHow can we keep the process fixed?
Control Charts Variable and Attribute Charts Implement Process control Project closure
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Why KPMGHighlighting our capabilities to deliver this service
11 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.
Business Excellence Practice: Overview
Service line/Solution Overview:About the service line/solution, FTE, etc. National resource pool of 15
consultants with average industry experience of 12 years. These include: Master Black Belts Black Belts Green Belt practitioners
Industry: Energy, retail, FMCG, utilities, port, hospitals, IT/ITES, government, Airport and others
More than 35,000 hours of services delivered to various clients
Standard methodologies and communication strategies to operationalise onshore-offshore delivery
Executed multiple projects leading to EBITDA, Margin, G&A and other cost improvements via Lean, Six Sigma, IE , TPM implementations
In Analytics domain: 7 Step approach from Problem to
Decisions; Focus on areas like Workforce
Management, Sales & Marketing etc.
Expertise in tools like R Technology Partnerships on the
anvil
Practice Overview
Service Offerings
Lean Six Sigma Advisory Facilitation Based Projects Full Scale Implementation
These may include TPM and specific Industrial Engineering projects as required.
Data Science Advisory 7 Step approach from Problem to Decisions;
Lean Six Sigma Training Lean Six Sigma Green Belt Lean Six Sigma Black Belt Training Lean Six Sigma Advanced Programs
Approach linking Data Science to Business Process Improvement using Lean Six Sigma
Key Differentiators
Experience in diverse industries like Manufacturing, FMCG, Retail, IT & ITES, Financial Operations, Clinical Research , ports, airports and Consumer Appliances
Solution mix of Lean, Six Sigma, TPM, and specific IE methodologies
First among the Big 4 to have Six Sigma Practice in India
Trained more than 14,000 participants on Six Sigma globally. Now approx. 200 per month
Adani Group Philips British Telecom SunTech
Key clients
Large and Mid market companies enrolled for KPMG Green & Black Belt Training
Black Belt Projects handled spanning diverse industries
Dedicated team of Six Sigma resources including Master Black Belts and Black Belts
500
600
15+
Matrix Cellular Oracle Madura Fashion Lifestyle Delhi Technological University
Reuters Symbiosis Institute of Operations Mgmt IITs IIMs
12 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.
Some Of Our Associations
13 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.
Some Of Our Associations
14 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.
Voice of Customer
The training in 6 Sigma methodology helped me plan very efficiently, a project currently on in my organization. The project is expected to help my organization immensly. The training changed the way I looked at such projects and I believe our team has achieved much more than what it would have without six sigma methodology
- Girish Raja, Six Sigma Public Program Participant, Pune
Hi Nitesh,The six sigma program with KPMG has helped me improve my understanding on the concepts of Process Improvement to a great length.Also, at my organization we have taken the initiative to train people and create a forum that is trying to adapt the Six Sigma principles as per our organization process and policies
- Priyanka Grover, Six Sigma Public Program Participant, Mumbai
I had attended the Six Sigma - Green Belt session in November 2007 and my overall learning experience has been very fruitful. The methodology (across industry examples) used to deliver the session has helped me to re-align my thought process and that has clearly reflected in the quality of my work... I was able to drive many process re-engineering project which have lead to dollar and manpower saves. Also now I am actively involved in global projects.
- Ketan B Kurani, Six Sigma Public Program Participant
Dear Sir,The project details are as follows:...Achievement:Cpk improved from 0.28 to 0.95.The sigma level improved from 2 to 4.1 sigma.Potential Savings after the improvement amounted to Rs.17304480 per annum.
- Nitu Sharma, Student Symbiosis Institute, Nasik
The course material is well structured & with proper guidance with well suited examples from all fields( manufacturing, software solutions, ITES etc.). Therefore a practical scenario was established during the courseit helped me in interview a lot since questions were asked about several quality & statistical tools & there significances
- Prashant Pareek, MBA Student, Symbiosis Nasik
Thanks for your guidance and support..training was really meaningful and fruitful for my career perspective. I have implemented the methodology in few of my company projects and achieved the unexpected results.One of my projects was At the end of the projects we were able to save plenty of time in entire cycle
- Alok Tripathy, Six Sigma Participant, Delhi
Commercial
16 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.
Commercials
Note: This fee does not include additional expenses such as food for the faculty, copying / duplication of training material, shipping charges, as applicable. The same will be charged on actual. KPMG will provide one hardcopy of training material prior to commencement of batch. Rest may be photocopied, as appropriate by your Institute. It will be our endeavor to keep the other expenses as reasonable as possible.
We are keen on continuing our relationship with Indian Institute of Management, Ranchi and value this opportunity to be of assistance. Considering our relationship and the time and effort for the program, we propose the following professional fees.
# Theme Activities Fees Notes
1 Lean Six Sigma
Green Belt
Training,
Evaluation and
certification
Kick off, Pre-Program Preparation and Organizational Understanding
Green Belt Program (4 days)
Training - INR 8,500/- per student (inclusive of all applicable taxes)
Considering
minimum of 40
students undergoing
this program.
17 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.
Sample Certificate
Contact Details
in.kpmg.com
The information contained herein is of a general nature and is not intended to address the circumstances of any particular individual or entity. Although we endeavor to provide accurate and timely information, there can be no guarantee that such information is accurate as of the date it is received or that it will continue to be accurate in the future. No one should act on such information without appropriate professional advice after a thorough examination of the particular situation.
2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.