1. Lean-Green belt six sigma program
Deployment Approach
capability development program
Operation excellence by Lean method
Lean-Green belt six sigma program
S G JOSHI

2. Six Sigma for best manufacturing practices.
It is an enterprise wide strategy that effectively develops a Inhouse /supplier capability and a desire within individuals to:
To adopt best practices in manufacturing excellence
New product introduction, Design for mfg ,assly technique.
To effectively manage process activities and performance
To solve business and quality problems
To improve decision-making
To improve the overall performance of the enterprise
LSS projects –
Lean Practices for WCM DWM, 5S,3M,KAIZEN,FLOW MFG,CELL MFG, Best engineering practices .
Lead time reduction
COST to manufacturing
First time right
On time delivery
Every officer to identify 3 projects as defined by top management in KRA.

3. How Six Sigma is Implemented and Applied Will Determine the Results
Categorization of Results
Below Average
Above Average
TOTAL QUANTITY OF
IMPLEMENTATIONS
Inferior
Excellent
RESULTS FROM SIX SIGMA
IMPLEMENTATIONS
How Six Sigma is Implemented and Applied Will Determine the Results

4. Multiple Factors Determine the Results Obtained …….. Y=f(X)
Global Quantification of Results
Multiple Factors Determine the Results Obtained …….. Y=f(X)

5. Factors that Influence Results
Y(results) = f(X)
X1 = Senior Executive engagement and commitment
X2 = Up front planning
X3 = Infrastructure Development
X4 = Proactive Champions that see the power of Six Sigma
X5 = Full-time Black Belts from “Among the Best”
X6 = Process Management through Green and Yellow Belts
X7 = Black Belts Project selection that makes an impact on the bottom line of the business
X8 = Financial evaluation system
X9 = Metrics and goals linked to corporate strategy for progress tracking
X10 = Project tracking system to measure progress
Initialization
Process Management

6. and Worker Responsibilities
Process Management & Improvement
Key Process Map
Key Process Map
Enabling Processes
Core Processes
Senior Management
Owned
Level 1
Manager 1
Manager 2
PCS Summary
PCS Summary
Middle Management
Owned
Level 2
Process A
Process B
Process C
Process D
Process E
Process Owner
and Worker Responsibilities
Level 3
Mgr A
Mgr B
Mgr C
Mgr D
Mgr E
Process Owners Use Process Management to:
Manage & supervise their operation •
Track & monitor process and results indicators •
Assure predictability and stability of the process •
Identify potential improvements •
Improve the process •

7. Process Management & Improvement
Measure
Analyze
Improve
Design of Experiment
And/Or
Solution Determination
Control
Black Belt Project
Process Control Q1 P1 P2 P3 P1 P2 Q1 P3
Q1 Indicator Chart
P1 Indicator Chart
Incapable Process
GB Project With YB Support
P2 Indicator Chart
P3 Indicator Chart
Out of Control
Process

8. 3 2 1 Six Sigma becomes the “Way We Think and Work” Core Competency
The Path to Self Sufficiency 3
What is Ultimately Achieved
Core Competency
Core Competency - The intellectual knowledge and capability of employees to quickly and accurately solve problems, to align and optimize business process and to make better decisions 2
The First Realization
Business & Process Management
System
Business and Process Management - The way we view our business efforts, set our expectations, determine our decisions, and the way we lead the Company to optimally satisfy all of our stakeholders. 1
Where Most Start
Quality Management
System
Quality Management - The set of strategies, tactics and practices collectively used as a Company to competitively achieve business objectives and to satisfy customers.
Six Sigma becomes the “Way We Think and Work”

9. Roadmap-LEAN -Six Sigma DMAIC/DMADV
Start
Validate Project Saving Rs
Define
Customers, Value, Problem Statement
Scope, Timeline, Team
Primary/Secondary Metrics
Current Value Stream Map
Voice Of Customer
Next Project
Celebrate Project Success
Measure
Verify specification
Measurement Capability (Gage R&R)
Correct the measurement system
Process map, SIPOC, Time cycles.
Normality test of data
Control
Standardize process ( WIs, SOP)
Mistake proof, SPC, Checklist
Establish metrics & frequency
Value Stream Review
Prepare final project report& closure
Leaders
Master
Black Belt
Quality Leader
Organization
Validate Project Saving RS
Black Belt Green Belt
Validate Project Results
Analyze (and fix the obvious)
Root Cause (Pareto, C&E, brainstorm)
Find all KPOVs & KPIVs*
FMEA, DOE, critical Xs, VA/NVA
Graphical Analysis, ANOVA
Cuurent Value Stream Map
Team Members
Improve
Optimize KPOVs & test the KPIVs
Piloting , monitoring & improving
Redesign process, set pacemaker
Visual controls
Future Value Stream Plan
Validate Project Saving/Improvement
*Key Process Output Variables
Key Process Input Variables
Green belt six sigma program
10/12/2013

10. Lean Six Sigma DMAIC Roadmap”
Input
Process
Output
Project Success
Celebration
Celebration, Best Project Recognition
Complete project review, Result validation, control establishment &results
Complete project review, Result validation, control establishment ,Documentation, Process Handing over to owners & results monitoring process
Validated steps & results Vs Goal, Documentation & Handing over
Project closure
at Site
Validated steps till that stage
Identified Route Causes
Improvement Plan
Progress Review
at Site
Problem analysis, experiment results ,Identified Root causes, Improvement plan progress &results
Review & Training
Module 3 (2 day)
Improve & Control
Validated steps till that stage
Identified Route Causes
Improvement Plan
Problem analysis, experiment results ,Identified Route causes
Validated steps till that stage
Action plan till next stage
Progress Review
at Site
Problem analysis, experiment results
Project charter with Sigma Level,
CTQ tree
Review &Training
Module 2
Analysis (2 Days)
Understanding of analysis tools & action plan till next review
Project Data, Problem Definition
Finalized project charter with Clear problem definition, measures and target
Mid Term
Progress Review
(Common)
VOC, Measurement Validation
Project charter with Sigma Level,
CTQ tree
Module wise training and implementaiton
Understanding of Overall six sigma approach & Detailed steps of Define & Measure
Training: Module 1
Define & Measure (2 Days)
Project Leaders &
core team members
Project specific Data-Defects, cost, occurrence, period etc
Action plan to be Carried out for till next review
Data on Major Issues & Impact (Quality/Bottleneck)
Project Selection
Team Identification
Prioritized projects with initial data
Team constitution ( Champion, Facilitator, Team Leader & Members) for each Project
Data on Customer ratings/process measures
Information on improvement initiative running
Six Sigma Awareness
Training (One Day)
Senior & Middle Level Leaders
Understanding of Usage
& steps of Six sigma
Information on Major issues (Quality/Bottlenecks)
Six Sigma Initiative
Kick Off 10 10