Six Sigma Green Belt

Agenda Six Sigma Journey - Makarand Kanade Competency Level Achievement - Mahesh Hegde Six Sigma Presentations Mr. Prashant Joshi - 10 mins Mr. Patidar - 10 mins Ms. Vimal Hule - 10 min Address by - Managing Director Distribution of Certificates to qualified participants Vote of Thanks - Sarika Joshi

Six Sigma Green Belt

Six Sigma Journey Recap in brief Uniqueness of the Program Execution and Monitoring process Achievements Future Plans

Six-sigma is a set of strategies, techniques and tools for process improvements Traditional Approach Problem Statistical Problem Six-sigma Approach Statistical Solution Solution Six-sigma is a systematic data-driven approach, which leads to sustainable solution to any problem

Recap and Uniqueness of the program Six Sigma drive was initiated in Force motors & Jaya Hind Industries since Dec13 The program is customized considering requirements of Force Motors. It is a goal oriented approach and Handholding for participants throughout the program instead of a just classroom trainings in the previous attempts Objectives of Six Sigma Drive Improve individual competency level for problem solving in a structured way Tangible benefits to organization Cultural Change Data based decision Customer focus Team working Selection of project Nomination for the course Training & project planning Hand holding and monitoring Final qualification

Uniqueness of the program Two unique training modules of total six days were designed with release of special syllabus book Module 1 – Three working days Module 2 – Three working days Six months are given for each participant to complete his / her project with DMAIC (Design-Measure-Analyse-Implement-Control) approach Latest problem solving tools of Shainin DOE are included. These are Non conventional and proven problem solving techniques. Few of the tools are, Component Search Paired Comparison Product Process Search Multi-Vary Analysis In house co-ordination, guiding, mentoring, supporting and reviewing at defined interval. External monitoring of the project progress with defined tollgate reviews and also Gemba review of the projects on the shop floor

Successor of Prof.Ishikawa Dr.Amasaka (Ex.GM Toyota Japan) Mr Mahesh Hegde Prof.Kume Deming Award Winner Successor of Prof.Ishikawa B.E.(Mechanical) –Sir.M.Visvesvaraya Institute of Technology-Bangalore Certified Six Sigma Black Belt from American Society for Quality (ASQ) One among the 4 Indian Qualified Trainers from Renault Nissan Institute France Trained by very known experts TQM in Manufacturing & New Product development - Prof.Washio Toyota Production System – Dr.Amasaka (Ex.GM Toyota Japan) Six Sigma Black Belt - Dr.Mikel Harry (Godfather of Six Sigma) Advanced Statistical Tools - Prof.Shu Yamada & Indian Experts

Execution and Monitoring process DMAIC in Six Sigma follows PDCA cycle Draw Conclusions Establish the Focus Examine the Current Situation Analyze the Causes Act on the Causes IMPROVE DEFINE MEASURE ANALYZE CONTROL Standardize Changes Study the Results Plan Do Check Act

Prioritisation is done by discussion with stake holders Short listed projects are being discussed with Mr Hegde Participant is nominated with project Chronic issues are being listed down Reduction in Customer complaints Reduction in Warranty failures Reduction in Rejection & rework cost Productivity improvement

Project Mentoring and Review Classroom Training Module I Define & Measure phases Module II Analyze, Improve & Control phases Project Reviews External Reviews by Mr. Mahesh Hegde Internal Reviews by Mrs Sarika Joshi Toll gate Reviews by Mr. Makarand Kanade

Project Mentoring for third batch Module I 21st ,22nd, 23rd of Dec-15 Module II 7th,8th and 9th March-2016 10 Tollgate Reviews 7 External Reviews 60+ Internal Reviews at Defined interval 6 Days Classroom Trainings along with written tests

Participation - 4 Qualification - 2 Batch -1 Jan 14 - June 14 Pune Participation – 9 Qualification – 6 Pithampur Participation – 8 Qualification – 8 Jaya Hind Participation - 4 Qualification - 2 Batch -1 Total Participation – 21 Qualification – 16 Batch – 2 Oct 14 – July 15 Participation – 9 Qualification – 9 Participation – 11 Qualification – 7 Participation – 6 Qualification – 4 Batch -2 Total Participation – 26 Qualification – 20 Batch -3 Dec 15 – July 16 Participation – 7 Qualification – 5 Participation – 15 Qualification – 8 Qualification – 2 Batch -3 Total Participation – 28 Qualification – 15 Total Participation – 25 Participation – 34 Qualification – 23 Participation – 16 Participation – 75 Qualification – 51 Saving 70 Lac per year Saving 85 Lac per year Saving 80 Lac per year Saving 2.35 Cr per year

List of Projects: Batch I

List of Projects: Batch II

List of Projects: Batch II (cont’d)

List of Projects: Batch III

List of Projects: Batch III( cont’d)

Following activities are proposed as Way forward To continue Six Sigma Green Belt Program (Proposed target for Pune – 20 & Pithampur – 30, Total 50 / year) To introduce Six Sigma Yellow Belt Program (These projects can be reviewed and monitored by Certified Green Belts) (Proposed target for Pune - 200 & Pithampur – 300, Total 500 / year) To initiate Six Sigma Black Belt Program for select participants (6 to 8 employees out of 51 qualified can be sent for Black Belt Program) To make organization structure for monitoring six sigma drive To add Six Sigma projects in the KPIs of respective divisions To give badges to qualified Six Sigma employees for yellow, Green and Black Belts

Journey has started………….. We are aspiring higher and higher heights of excellence