confederation of indian industry - cii-iq.in newletter.july 2016.pdf · cii iq has also provided a...

Confederation of Indian Industry

LEAN SIXSIGMA

Volume 1 | Issue 1 | July 2016

N E W S L E T T E R

BusinessResults

Capabilty &DNA Building

CustomerSa�sfac�on

Revenue Enhancement

Produc�vity &Delivery

Quality &Reliability


LSS Newsle�er | July 20162

This year the Lean Six Sigma ver�cal of the CII Ins�tute of Quality entered into its second year of opera�ons. The renewed focus of the team during the first two quarters of 2016, was to set standards for Lean Six Sigma cer�fica�on, expand the number of in-company engagements and provide opportunity for the industry to learn from each other.

The team organized its first Study Mission on Health Care to NHS Hospitals in UK with an objec�ve to introduce the doctors and administra�ve heads of Indian Hospitals to the con�nuous improvement prac�ces deployed to improve efficiency, effec�veness and customer experience. During the 1 week visit, mission par�cipants visited King Edward VII's Hospital, St George's University Hospital, King's College Hospital NHS Founda�on Trust, University of Liverpool, School of Medicine, Royal Liverpool Hospital and Pall Mall Medical.

An Updated Lean Cer�fica�on Course – The Toyota Way was launched this year and the first two batches were held in a factory environment at VOLVO Construc�on Equipment Division, Bangalore and at Mahindra & Mahindra, Mumbai. This cer�fica�on course was designed to present Lean Methodologies in line with its original source, inclusive of prac�cal tools, techniques, concepts and working methods.

CII IQ has also provided a pla�orm for Industry to access Award Winning Case studies on Lean Six Sigma from their respec�ve loca�ons through a web based monthly forum. This ini�a�ve was launched with an objec�ve to share the best prac�ces with industry par�cipants to enhance capability and competence.

I hope that you will find this second edi�on of the LSS Newsle�er useful and looking forward to your guidance and support for this Na�onal cause of improving opera�onal excellence.

R MukundanChairman, CII Ins�tute of Quality

Managing Director, Tata Chemicals Ltd.

Chairman’s Message

Training & Consultancy Overseas Plant Visit to LeanPractising Companies

Handholding for Lean &Six Sigma Implementation

Benchmarking Study - Plant Diagnosis

Conferences and Competitions


LSS Newsle�er | July 2016 3

In-Company Certication and Transformation ProgramBHARAT FORGE LIMITEDA 14 days Black Belt Program has been launched at Bharat Forge Limited with 26 high impact projects addressing improvement in Quality, Cost, Delivery and Customer Sa�sfac�on. The CII faculty designed the course to align with the DMAIC and also to ini�ate Project work early into the course. The result was a marked improvement in the nature of problems selected and in the results that were par�cularly impressive in terms of issued resolved as well as their impact on business.

It has been a very special journey for BFL to associate with the CII Ins�tute of Quality that has brought tremendous understanding on the quality front and will enable us to keep pushing the global compe��ve barriers of technical excellence.

RASTRIYA ISPAT NIGAM LIMITEDLean Six Sigma team is engaged with Rastria Ispat Nigam Limited, to provide support in iden�fying improvement opportuni�es, train managers and provide coaching using Lean Six Sigma Methodology. Two batches covering over 60 managers have completed delivering significant benefit in Quality, Produc�vity, Customer Sa�sfac�on and Cost Reduc�on. The third batch with around 30 par�cipants is scheduled for August 2016. This will also lead to cer�fica�on of the managers as Green Belt which will enable DNA building within the organisa�on.

Client Speak

This Training Program on " Lean Manufacturing - The Toyota Way" improved my knowledge about Lean manufacturing. It helps me to find out what mistakes I did in Lean projects while implemen�ng Lean tools in the organiza�on & give a chance to improve it. It clarified my queries about Lean tools in a prac�cal way such as plug games & factory visit to Mahaindra & Mahindra, Kandivali. While session over six sigma added some knowledge in my own memory data bank & also it helped me to get some knowledge about data analysis with help of Mintab to iden�fy the problems. Thanks for CII Ins�tute of Quality for arranging such a valuable program.

Sumit Ganoje, Par�cipant of the Programme

“Training Program at Mumbai on 'Lean- The Toyota Way' was a perfect Mix of Theory and real life examples through Case Studies and Lego Game Simula�ons . Concepts were very well explained followed by the Shopfloor Visit helped us to relate the Concept and lean culture on the shopfloor .We learnt the experiences of operators and improvement teams during the Implementa�on, which were mo�va�onal and displayed “we can do it a�tude” .Six Sigma explained in non manufacturing were excep�onal “.

-- Brijesh D. PrabhuManager – Con�nuous Process Improvement

Commscope



Capability Building & Certication CoursesLSS Team have built internal curriculum in line with the Global Standards in the following areas

Ÿ Lean Prac��oner and Six Sigma Green BeltŸ Lean Expert and Six Sigma Black BeltŸ Six Sigma Master Black Belt for Cer�fied Black BeltsŸ Design and Analysis of Experiments including Taguchi Methods for

New Product DevelopmentŸ Lean The Toyota Way in Factory Environment (Launched during 2016,

two programs completed one at Volvo and one at Mahindra and Mahindra)

The above programs are being offered both open and In-house. During the first half of 2016, a Cer�fica�on Course on Lean Six Sigma Green Belt & Black Belt Cer�fica�on Program at Bengaluru, Gurgaon & an in-house program in

Trelleborg Sealing Solu�ons were held. These cer�fica�on Courses were of 5 days which include building capability on Lean Six Sigma Concept and Methodology.

The objec�ve of the training was to give the par�cipants an insight on Lean, Lean tools, Lean principles, DMAIC approach. SIPOC, various tools like Graphical analysis TOH, ANOVA, Regression, Advanced Lean Concepts, Change Management, Factorial Designs, Design of Experiments, Control Chart and Control Plans. Par�cipants were made to solve case Studies on the above tools & techniques using MINITAB so�ware.

From January to June 2016 we have trained around 60 Green Belts & 50 Black Belts. The Companies a�ended were:Green Belt & Black Belt Bengaluru: Anand Engineering Pvt Ltd, Intervet India Pvt Ltd, L&T Ltd, Murugappa Morgan Thermal Ceramics Ltd, Volvo India, Hindustan Coca Cola, Trelleborg Sealing Solu�ons, Xerox, TVS Motor Company Limited ,Tractors and Farm Equipment Ltd, SE Blades Ltd, HSBC Technology and Services. Green Belt & Black Belt Gurgaon: RACL GearTech, Godrej & Boyce Mfg. Co. Ltd., Woodward, Prakash industries Ltd, HDFC Life, Times Group, E&Y and many more

BUILDING CAPABILITY TO ENHANCE AUDIT EFFICIENCY & EFFECTIVENESSA two day in-house workshop was conducted at Vodafone, Pune on 'Building Capability to Enhance Audit Efficiency & Effec�veness'. This program covered the topics such as Internal audit objec�ves, organiza�onal context & process approach, audit program, planning & prepara�on conduc�ng audits, audit checklists, audit repor�ng, audi�ng specific aspects, exercises.

Anurag SeksariaPrincipal Counsellor & Head Lean Six SigmaCII Ins�tute of Quality+91 99022 [email protected]

Mamta RaiExecu�ve OfficerCII Ins�tute of Quality+91 99860 [email protected]

Vinay Kumar S PExecu�veCII Ins�tute of Quality+91 97384 [email protected]

LSS Team

Par�cipants of the Programme



TRAIN THE TRAINERS - INFOSYS, BANGALORE CII Ins�tute of Qualityorganized a 4 days Train the Trainer Program on Lean Six Sigma for the Master Black Belt trainers from Infosys.

Objec�ve of our training was to help them in:Ÿ Enhance the training and delivery to make it more impac�ul

for the par�cipantsŸ How certain concepts can be made simpler and more

effec�ve in deliveryŸ New tools & techniques in six-sigma which was not covered

in their present curriculum

Before we started our Training Program we were asked to review their current academic curriculum & also we collected from each par�cipant their expecta�ons from the training Program. A case study was shared through Skype by Head of Business Excellence from Max Life Insurance Ltd.


“The training program gave me immense knowledge on benefits of lean manufacturing, the method which could bring dras�c improvements in produc�vity. The exercises done during the training program and the case studies presented were helpful in understanding the steps in Six Sigma and methods of solving problems with six sigma approach. We were able to witness the benefits of Lean manufacturing over conven�onal batch produc�on process, with an example of Lego game played during the training”

Par�cipant from Trelleborg

Client Speak

CERTIFICATION COURSE ON LEAN MANUFACTURING - THE TOYOTA WAYIn today's compe��ve market environment , companies both in manufacturing and non-manufacturing sector, have applied Lean and TPS approach successfully to improve produc�vity, reduce rejec�ons and gain compe��ve advantage. In the current scenario, Lean manufacturing System, in its purest form which is the Toyota Produc�on System has become a phenomenon for emula�on and prac�ce, irrespec�ve of the type of product being manufactured.

CII Ins�tute of Quality organized a Cer�fica�on Course on Lean Manufacturing - The Toyota Way at VOLVO, Bangalore in February and at Mahindra & Mahindra, Mumbai in April. The 4 days course was designed to present Lean Methodologies in line with its original source, with many of the prac�cal tools, techniques, concepts and working methods. The objec�ve of the training was to give the par�cipants an insight on Lean, Lean tools, Lean principles, how to use lean as tool in the industry using game methodology. Par�cipants were made to prac�ce on VSM, 8D principles, inventory reduc�on & how to increase the produc�vity by playing Lean-plug games & a shop floor visit to the Company.

This course was a�ended by 45 par�cipants. Companies par�cipated are from Roop Polymers Limited, J K Fenner (India) Limited, Tata Global Beverages Ltd, Tecumseh Products Company, Qsource Interna�onal, SKF, ACG Pam Pharma Technologies Pvt. Ltd, Tata Global Beverages Ltd Larsen & Toubro, Electrical & Automa�on, J.K.Fenner (India) Ltd, Johnson & Johnson Aurangabad, India Nippon Electricals Ltd, Veer - O - Metals Pvt Ltd,, Innova Rubbers Pvt. Ltd, PRICOL LIMITED, JK TYRE & INDUSTRIES Ltd, NTTF, Bangalore, Endress + Hauser Flowtec (India) Pvt. Ltd, Siemens Technology and Services Private Limited, Godrej & Boyce Mfg. Co. Ltd, Andrew Telecommunica�ons India Pvt. Ltd & many other companies.




WebinarLEAN SIX SIGMA AWARD WINNING CASE STUDIES - WEBINARS In order to provide a door step knowledge on Lean Six Sigma Projects/ case Studies, CII IQ has ini�ated series of Award winning Case Studies through a webinar pla�orm. These 90 minutes web based Sessions will provide an opportunity to get complete details on the projects directly from the teams who have executed them. The par�cipants will have the opportunity to raise their ques�ons and get responses from the presen�ng organiza�on.

HighlightsŸ These case studies are the winners of 9th CII IQ Na�onal Six Sigma

Compe��on. Winners are from all the categories/sectors like Manufacturing industry, process industry, new product development, Service IT, ITES.

Ÿ One Case Study per month. Can enroll during any month. Ÿ Help to iden�fy right Projects and link with overall business

objec�ves of the organiza�on, so�er aspects of managing change.

As of now 2 Case Studies have been presented by:The Times of India: “Reduc�on in Direct Variable Cost”This case study achieved a significant Rs. 2.50 crore reduc�ons in cost. The usage Chemicals which was not environmental friendly has been reduced. This project also worked with key lessons learned and how integra�on from shop floor to Top Management was achieved to enlighten the minds of people and scale towards “Excellence in Manufacturing.” This Best prac�ce of the company has been incorporated in 13 BCCL (Benne� Coleman & Co. Ltd) print sites in India.

TAFE Ltd.: “Improve Semi Knock down Processes Efficiency through Lean Principles”The outcome from the company's best project is related to suppor�ng company's KPI in terms of reducing waste, applying a new logis�c technique called SKD (Semi Knocked Down) a completely disassembled kit. The project provided the company with improved 118 mins to 53 mins Takt �me, material-in flow op�mized with JIT process to accommodate the increased volume by 500 SKDs per month leading to improve first �me build quality from and increased produc�vity index.

Other presenta�ons scheduled this year - S�ll to Present: Ashok Leyland, Amara Raja Ba�eries, Coca-Cola, TATA Chemicals, Max Life Insurance etc.,

Par�cipa�ng Companies: Mo�lal Oswal, Times Of India, L&T Electrical & Automa�on, Idea-Aditya Birla, Sodexo, J K FENNER, Infosys, Tata Chemicals, Brakes India & Vishay Components India Pvt. Ltd.

These webinars pla�orm organized by CII IQ was a nice experience for me and for my company.

The whole opera�on was new to us and we came to know the process and opera�ons of these Companies. The step by step advancement of the project will help to address our organiza�onal problems for similar issues. Using of the tool "Heijunka matrix analysis", "Visual Instruc�on for different models of work and " O p e r a t o r w i s e a n a l y s i s interpreta�on" impressed me a lot and I am planning to use these tools in the LSS project of our company also. In a nutshell we can benchmark the use of tools for our Company LSS projects also “

Abhik Saha Tata Chemicals Ltd.

Client Speak



International MissionLEAN & SIX SIGMA HEALTH CARE MISSION TO UK

CII Ins�tute of Quality organized a study mission on Lean & Six Sigma Mission to UK for health care industry. This mission brought understanding & knowledge on how six sigma plays a major role in the health care industry. The program was carried by various superior Doctors / consultants who had lot experience in the subject of health diagnosis also in the quality of the process / opera�ons like Presenta�on on quality, process innova�on and customer sa�sfac�on and program in Theatre Management, Session on KCH's approach and experience of service & process transforma�on etc.

In this mission par�cipants visited King Edward VII's Hospital, St George's University Hospital, King's College Hospital NHS Founda�on Trust, University of Liverpool, School of Medicine, Royal Liverpool Hospital and Pall Mall Medical etc., and clarified various doubts.

This Mission was a�ended by 12 par�cipants like Senior Consultant Pediatrician, CEO, and Head of Clinical Services (Mission Leader), Managing Director, Chairman, Prac��oner and Directors of Narayana Hrudayala Hospital, Anexas Europe, Manipal Hospitals, Medical Trust Hospital, SKS Hospital, KLE University's Jawarharlal Nehru Medical College, Belgaum Karnataka, Yashoda Super speciality Hospitals, Narayana Health, Star Hospitals, Yashoda Super Speciality Hospitals, Anexas Consultancy.

CII IQ has also organized study missions to Raymond's, TAFE, TVS, and TOYOTA in which more than 60 people a�ended.

It was a great experience to interact with professionals of world class NHS hospitals and to learn about their best prac�ces. They have novel methods to incorporate the principles of Lean Six Sigma in health care industry. Thanks to CII team for the splendid job of packing so many useful visits within short dura�on. The visit will certainly have its posi�ve impact on our hospitals and pa�ent care.

Dr Komal Prasad CMBBS, MS, DNB, M.Ch (Neuro),

PGDHHM, PGDMLE, MNAMS

Client Speak

Par�cipants of the Mission

UPCOMING PROGRAMMESLean Prac��oner & Six Sigma Green Belt Cer�fica�on Program1-5 August, Pune | 22 - 26 August, Bengaluru | 17 - 21 October, Chennai

Lean Expert & Six Sigma Black Belt Cer�fica�on Program Phase I1-5 August, Pune | 22 - 26 August, Bengaluru | 17 - 21 October, Chennai

Lean Expert & Six Sigma Black Belt Cer�fica�on Program Phase II19 - 23 September, Pune | 12 - 16 September, Bengaluru | 21-25 November, Chennai

Lean- The Toyota Way | 4 - 7 October, Chennai

THE NATIONAL LEVEL SIX SIGMA COMPETITION

1 - 2 September, Bangalore


ABOUT CII INSTITUTE OF QUALITY

CII Institute of Quality is the leading authority in Quality Enhancement among organization and industries. Over the past century,

CII has provided Indian Industries with the support, systems and tools to make a mark in the competitive world. It is realized that

the best way to enhance an organizations competitiveness was through the quality route.

What started as the Total Quality Management Division (TQMD) in the mid-eighties has now evolved as CII Institute of Quality. As a

champion of the Quality movement, CII-IQ is powered by the responsibility of enriching the lives of its members, improving their

workplaces and making the world a better place by applying quality tools, techniques and systems. CII-IQ provides the best of its

kind training and consulting services to organizations to help improve their performance and set a standard of excellence.

CII IQ has tied up with several international organizations to bring their best practices in India. It has helped several organizations

improve their Total Quality Management Systems besides helping them win recognitions.


The Mantosh Sondhi Centre

23, Institutional Area, Lodi Road, New Delhi – 110 003 (India)

T: 91 11 45771000 / 24629994-7 * F: 91 11 24626149

E: [email protected] * W: www.cii.in

CII Institute of Quality

The K N Shenoy Centre

Near Bharat Nagara II Stage,Viswaneedam Post,

Magadi Road,Bangalore 560 091, Karnataka,India

Tel: +91 80 23580315/ 2328 9391- 6085 Fax : +91 80 23580314

E: [email protected] W: www.cii-iq.in

confederation of indian industry - cii-iq.in newletter.july 2016.pdf · cii iq has also provided a...

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