1. Six Sigma Green Belt

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

3. Six Sigma Green Belt

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

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

13. Participation - 4 Qualification - 2
Batch -1
Jan 14 - June 14
Pune
Participation – 9
Qualification – 6
Pithampur
Participation – 8
Qualification – 8
Jaya Hind
Participation 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

14. List of Projects: Batch I

15. List of Projects: Batch II

16. List of Projects: Batch II (cont’d)

17. List of Projects: Batch III

18. List of Projects: Batch III( cont’d)

20. 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 & 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

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