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Six Sigma Applications in Manufacturing Sector

About Workshop

Six Sigma is by far the most successful Management Approach and has delivered results. Simply defined, Six Sigma is a powerful data driven, customer focused management methodology that delivers validated improvements in profitability and productivity. Six Sigma is a disciplined use of applied science that improves profits by creating and systematically replicating breakthrough improvements. Six Sigma and lean manufacturing concepts in manufacturing sector provides a roadmap, a step by step method to achieve desired results, while other philosophies talk about concepts, standards and ideas. Six sigma is not a certification concept rather it’s a business process reengineering tool which had helped big companies to save a lot by improving overall standard of the company. It begins with top management commitment and strictly follows a top to down approach. Six Sigma projects are identified with respect to business deliverables i.e., impact on productivity, profitability and customer satisfaction. The ideal Six Sigma projects are for those complications that do not have obvious solutions and need digging beneath the visible scenario. The expected outcome of six sigma projects is reducing process variations and thereby decreasing process defects to the tune of 3.4 defects per million opportunities instead of current defect level of 3% - 5% in most apparel / textile manufacturing industries. It means that, instead of getting a 95% - 97% product realization, the process will deliver up to 99.99966% product realization and process stability.

OBJECTIVE
To provide hands-on practice on Six Sigma tools for implementation, so that they can initiate and carry through Six Sigma Projects at their workplace.

HOW PARTICIPANTS WILL BENEFIT
The participants can learn about usage of scientific and statistical tools on the principle of “Define–Measure–Analyze–Improve-Control (DMAIC)”. They will be guided to identify value adding and non-value adding process variables which are having a impact on Key process output variables. They can understand methods to predict possible reason for failure and focus on stabilizing the process well in advance. Sufficient guidance for implementing proven methodologies such as Process mapping, FMEA, Capability index and other statistical control charts would be taught, enabling the team to stabilize the process.

Workshop topics to be covered:

Day I - Six sigma overview, Define and Measure phase
SESSION I (9.00 AM – 10.45 AM)
---Overview of Six Sigma, its impact in process engineering.
---The six sigma language, DMAIC Methodology overview.
---Financial benefits of six sigma.

DEFINE PHASE:
---Project Definition & Project charter.
---Gathering Voice of the Customer, Voice of Business, Support for Project

SESSION II (11.00 AM – 1.00 PM)
---Translating Customer Needs into Specific Requirements – Critical To Quality (CTQs)
---SIPOC Diagram
---Developing a Business Case.
---Chartering a Team
---Defining Roles and Responsibilities
---Define phase review

SESSION III (2.00 PM – 3.30 PM)
MEASURE PHASE:
---Process Mapping (As-Is Process)
---Understanding Variation
---Data Attributes (Continuous Versus Discrete)
---Measuring Process Capability
---Measurement System Analysis

SESSION IV (3.45 PM – 5.00 PM)
---Calculating Process Sigma Level
---Data Collection Techniques
---Visually Displaying Baseline Performance
---Data Collection Plan
---Measurement Phase Review

DAY II – ANALYSE, IMPROVE AND CONTROL
SESSION I (9.00 AM – 10.45 AM)
ANALYSE PHASE:
---Data Segmentation and Stratification, Visual Display of Data.
---Detailed (Lower Level) Process Mapping of Critical Areas.
---Verification of Root Causes : Cause and Effect Analysis (Ishikawa)

SESSION II (11.00 AM – 1.00 PM)
---Value-Added Analysis.
---Determining Opportunity for Improvement
---Analyze Phase Review

IMPROVE PHASE:
---Brainstorming
---Multi-Voting

SESSION III (2.00 PM – 3.30 PM)
---Selecting a Solution
---Failure Modes and Effects Analysis (FMEA)
---Poka Yoke (Mistake Proofing)
---Piloting Your Solution
---Implementation Planning
---Improve Phase Review

SESSION IV (3.45 PM – 5.00 PM)
CONTROL PHASE:
---Assessing The Results of Process Improvement
---Statistical Process Control (SPC) Overview
---Developing a Process Control Plan
---Control Phase Review

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