KPMG- Lean Six Sigma Boost your career. Today.

“Quality cannot be copied; there is no step-by-step cookbook that applies equally to all company situations and cultures.”

What is Six Sigma?

Read in a clock-wise manner

Quick Wins

Measured

Continuous

Improvement

“Six Sigma is a quality program that, when all is said and done, improves your customer’s experience, lowers

your costs, and builds better leaders. — Jack Welch

Six Sigma at many organizations simply means a measure of quality that strives for near perfection. Six Sigma

is a disciplined, data-driven approach and methodology for eliminating defects (driving toward six standard

deviations between the mean and the nearest specification limit) in any process – from manufacturing to

transactional and from product to service.

The statistical representation of Six Sigma describes quantitatively how a process is performing. To achieve Six

Sigma, a process must not produce more than 3.4 defects per million opportunities. A Six Sigma defect is

defined as anything outside of customer specifications. A Six Sigma opportunity is then the total quantity of

chances for a defect.

According to the Six Sigma Academy, Black Belts save companies approximately $230,000 per project and can

complete four to 6 projects per year. (Given that the average Black Belt salary is $80,000 in the United States,

that is a fantastic return on investment.) General Electric, one of the most successful companies implementing

Six Sigma, has estimated benefits on the order of $10 billion during the first five years of implementation. GE

first began Six Sigma in 1995 after Motorola and Allied Signal blazed the Six Sigma trail. Since then,

thousands of companies around the world have discovered the far reaching benefits of Six Sigma.

Benefits and Career Opportunities with a Six Sigma Certification

There is huge demand for Six Sigma professionals with experience, such as a Six Sigma Green Belt , a Six Sigma

Black Belt , a Master Black Belt, and a Champion.

Opportunities Available

With companies hiring Six Sigma professionals more than ever, there is no dearth of jobs available with some of the

best companies. Many qualified Six Sigma professionals that also have extensive experience also have the option of

opening their own consultancies.

A Six Sigma Green Belt career can be both challenging and fulfilling, and can encompass a variety of job options.

While the Green Belt designation is the first of several levels of Six Sigma certification available, it still carries

considerable weight in the business community and may give job candidates an edge in obtaining career positions with

some of world’s most respected companies.

The principles of Six Sigma are so widely applicable that employees skilled in their use are often aggressively sought-

after and highly valued. Whether you intend to embark on a Six Sigma Green Belt career path or use Green Belt

certification as a stepping stone to a higher level of expertise, professionals should consider their options carefully and

understand what types of job opportunities are available.

Benefits and Career Opportunities with a Six Sigma Certification

Professionals with Green Belt certification should have a comprehensive understanding of the basic tenets of

Six Sigma and should be able to apply its principles to their work on a daily basis. Common positions suited

for Green Belts include mid- to upper-level project managers, process engineers, consultants and

manufacturing engineers.

Typically, job-search sites post ads from companies offering Six Sigma Green Belt career opportunities.

Employers such as UnitedHealth Group, Honeywell, GE and Volkswagen have been actively seeking

professionals with Six Sigma certification to fill a variety of positions*, such as:

Lean Six Sigma Consultant

Lead Manufacturing Engineer

Process Development Engineer

Compliance Structural Engineer

Reliability Engineer

Operating System Specialist

Senior IT Project Manager

Warehouse Operations Manager

Business Process Analyst

Data Scientist

Project Engineer

Director, Performance Excellence

Benefits and Career Opportunities with a Six Sigma Certification

If we told you this certification is your entry ticket to the land of better opportunities and higher salaries, would you believe us? If we told you the

KPMG Lean Six Sigma Program was a comprehensive one designed to make you stand out of the crowd, improve your business acumen, sharpen your

analytical skills and make you catalysts of change to be coveted within any organization, would you believe us? If we told you this is THE course that

bridges that gap between students and professionals creating better leaders for tomorrow, would you believe us? Does this sound as if we are promising

you the whole world in a neat package with a pretty pink ribbon tied around it? Well, we just are.

Now, between the two of us, the first thing most of us see when offered a job is a package, right? You can be truthful, this not being a HR interview!

Yes, there you go…

Let’s talk figures then. When you’re so keen about making money why don’t you do that one single certification that can get you not just a job, rather

you’ll land in a world of success. You don’t trust us, then let us talk to you straight with the fact sheet.

Six Sigma Black belt project manager- The average salary for the post is Rs 1,020,072 in India. The cherry on the top is that you don’t need to have a lot of experience to prove yourself for the post. All that you need is project management skills and that can be easily learnt with KPMG Six sigma.

Six sigma certified Quality Manager- The salary ranges for this one from 540,250 – 1,694,160.

Six sigma certified process improvement manager- The salary range is 465,398 – 1,634,957.

Six sigma certified operations manager- The salary range is 528,738 – 1,992,000.

Six sigma certified quality assurance manager- The salary range is 489,357 – 2,246,889

Still reading? Do I need to say more after the figures. Rush and get certified from KPMG and then you’ll know what is Living life, King size.

Applicability of Lean Six Sigma in Engineering- Be a Leader with KPMG Six Sigma

Engineering is a broad discipline with varied streams categorized according to their application areas. The scientific knowledge implemented through engineering is evident in

every invention you can think of but the task does not end up here. There has to be a process to optimize each invention, simplify complex processes and implement integrated

systems of people, knowledge, money and equipment. This is when Industrial Engineering comes in the picture. Instrumentation and control, it’s a completely core branch. No need of the managerial concepts like Six sigma. Just when you think that, you make yourself fall behind. It’s not a failure just in terms of monetary losses but rather a failure of

lifetime! While you ignore Six sigma, you actually ignore the analytical skills of yours. Since Six sigma is not a concept, it’s a revolution that can turn your industry upside down.

Before you question the existence of Six Sigma in Industrial Engineering, I would like to tell you that it was Henry Ford, Founder Ford Motor Company, who introduced the

notion of providing financial incentives to employees to increase the productivity of Ford industries. A brilliant idea indeed but are you wondering what it has to do with either of

the topics here.

Industrial Engineering is all about making teams of non industrial engineers to work on improvement projects. Six Sigma is the one that lets you do that. The

standardized approach of Six Sigma when imparted scales the count and level of improvement projects across the organization. Its data driven methods helps to pipeline the tasks

at ease. Six sigma can offer help in the following ways:

• Statistical tools build an infrastructure of people in the company that are experts in all the fields and hence prove themselves useful to the industrial engineer

• Presence of experts eliminates errors along with reducing the variability in business and manufacturing processes

• Enhance the product quality that can be attributed to efficiently monitored workforce and streamlined processes

Six Sigma has undoubtedly become the need of the hour. Six sigma is a widely accepted quality management system, focuses on achieving 100% perfection and has been a tested

phenomenon in tech giant companies like General Electric and Motorola. So while you think it’s an all engineering task then you ignore the crux that lies in KPMG Six sigma.

Engineering can manufacture but quality comes with Six Sigma. Upvotes are automatically generated for people who are certified with KPMG Six Sigma. The advancement

witnessed in technology today does not demands engineers but experts. The extra edge is a must and when you’re an Industrial Engineer you cannot possibly even think of

lagging behind. After all you’ll handle a bunch of people. Moves are trusted when they are certified.

Last but never the least, 1.5 Million engineers pass out every year in India but they’re engineers not experts. So either you get to join the millions or lead the millions with KPMG

Six Sigma.

Civil Engineering

Why Six Sigma in Civil Engineering?

A few facts

• Is a civilization possible without civil engineers? Can defects and wastages be minimised by induction of KPMG Six Sigma in construction Industry- A resounding

YES!

• As per recently concluded survey construction industry has become the 2nd largest industry in India. During the last few years, enormous growth in infrastructure

has been found.

• But how to Minimize the waste to optimize the profitability is still a concern.

• In Construction Industry anything which does not meet requirement is deemed to be called as a “ Defect “ and here KPMG Six Sigma Plays a pivotal role in meeting customer demand, reducing cost borne by the company, avoiding delays.

Below are few staggering facts on construction industry:

• 91% of the projects are delayed.

• 94 % of the projects overrun in cost by 15 to 20 %.

• And round by 99 % of the time expectations don’t meet reality.

Why Six Sigma in Civil Engineering?

All in All main goal of KPMG Six Sigma is to manage material, time, manpower and capital efficiently and effectively KPMG Six Sigma includes providing:

• Structured methods of improvement to reduce waste

• Shorten production time

• Promoting concurrent work, accelerating activities, improving planning and control and ultimately high levels of customer satisfaction

Some major common defects that occur in the construction industry are as follows:

• Punctuality and Completion of projects on time

• Contractor generated cost-over run

• Not pertaining to the expectations of clients

These should be easily weeded out by the application of Six Sigma methodologies and will result in better outcomes, more productivity and increased customer

satisfaction.

Benefits of Applying KPMG Six Sigma in Civil Engineering

By following below KPMG Six Sigma, construction industry can improve their profit & good quality of work for: -

• Better understanding of Project

• Time line given to the project

• The challenges involved in the project & plans to overcome the same

• Safety of the work environment

• Better knowledge of market rates

• Better understanding of Competitors

• Major wastes and causes of delays

• Defects, reworks- their occurrence and frequency

• Control & improve the quality of work

• Compiles overall investment & benefits

• Validate the results & saving after the completion of project

KPMG Six Sigma tools help in gathering and analysing prevailing data and place it with your current ambition. There should be a lot of scope for KPMG

Six Sigma in construction as you can statically analyse the way workers perform their site activities, knowing the numbers of skilled workers you have on

your team to meet task.

Applicability of Six Sigma in Civil Engineering

Sample Projects

• Enhancing Supplier Quality

• Improving safety and reliability of finished buildings

• Reducing Manufacturing defects at each stage

• Using Design FMEA to understand and prevent any possible design failures

• Reducing variation in all the critical parameters that impact the finished product

• Improving the overall incoming material quality

• Reducing costs and delays

• Reducing time to construct

• Reducing design defects

• Reducing Supplier Lead Time i.e. the time taken by each supplier to deliver raw material

The application of six sigma was very much successful at Tata Steel, Jamshedpur in the case of eliminating packaging defects,

accounting errors, other quality assurance points. It has been tried in maintaining the quality of structural fabrication & erection work

of an ongoing steel project on pilot basis and the results were encouraging and reproducible!

Why learn the Methodology of Six Sigma?

Why learn Methodology

• It is a universal concept

• Depth and understanding of structured defect reduction technique

• Only methodology to aim for near zero production defects

• Concepts of data based problem solving and innovation can be applied in decision making

• Will help making data driven and logical decisions, strengthening leadership, belief and fostering motivation

Companies in the construction industry that have implemented Six Sigma in their manufacturing processes have gained tremendous

tangible benefits and covet trained Six Sigma Green and Black Belts who can take on dual roles in Lean Six Sigma projects.

Though the demand for human resources in the civil industry is fast booming, there is an urgent need for experts and not just

engineers. Will you take the baton in your hand and start leading as an expert? If your answer is yes, the time is now and the path is

KPMG Six Sigma!

Applicability of Six Sigma in Civil Engineering

Successful Implementations

Quality work reduces cost, improves schedule, and, in doing so, satisfies our customers. We believe in achieving quality by making solid decisions based on

facts, identifying issues before they occur, promptly fixing problems should they materialize, and inspiring every person on a project to "do it right the first

time.“ - Bechtel

Some successful implementations of the six sigma methodology in construction industry include Bechtel, DLF and Tata Steel-

Jamshedpur!

Bechtel is an industry leader in its adoption of Six Sigma. This discipline is a data-focused approach to establishing how processes perform, identifying weaknesses, and

identifying and guiding solutions that result in better performance and capability. Bechtel leverages Six Sigma processes to help deliver project budget and schedule

certainty, and mitigate project risk. Since the program inception we have:

• Trained more than 700 Bechtel, delivery partner, and client Black Belts

• Trained more than 4,000 staff as Champions, Green Belts, and Yellow Belts

• Delivered more than $2 billion in total installed cost savings to our customer projects

Six Sigma Innovation- Transforming a Victorian Tunnel for modern trains

Client Situation

The Crossrail project is the biggest construction project in Europe and Bechtel is supplying project management and execution capability as the project delivery partner

(PDP) within a fully integrated team. The scope consists of 13 miles (21 kilometers) of twin bore tunnels and seven new stations.

The project runs through the center of London and joins train services from east and west of the city including a link to the UK’s largest airport, Heathrow. An unusual

and critical challenge of the job would to modernize the Connaught Tunnel, a Victorian tunnel built for Victorian rail use, to meet the space needs for the new electrified

trains.

The Challenge

Crossrail uses overhead lines to power the trains, reducing the available space in the Connaught Tunnel, a cut-and-cover tunnel built in 1878, for steam train use.

Therefore, the base of the tunnel needs to be deepened by approximately 6.5 feet (2 meters). The deepening of the tunnel is referred to as “invert replacement” and it will place in the east and west ends of the Connaught Tunnel—a total of aproximately 360 feet (110 meters). This work has to be completed as per the project baseline

schedule of 30 weeks and at the same time prevent any risk of tunnel collapse during construction.

Action Implementations

• The objective: Reduce the cycle time of invert replacements

• An early step undertaken by the team was to map the invert replacement process as anticipated to take place. This step proved to be helpful as it clarified expectations

and compromises

• A Failure Modes and Effect Analysis (FMEA) workshop was held to ensure that the agreed solutions were implemented on site removing re-occurring risks

• By this point, the scope and challenges were identified. It was time to determine whether the proposed plan would work as expected and whether it would support

Cross rail's schedule. Since there was no production data available, iGrafx software was used to create a model to simulate the process based on the proposed plan

Six Sigma Innovation- Transforming a Victorian Tunnel for modern trains

Action Implementations

• The baseline total time predicted by the simulation for replacing the 250 feet (75 meters) of inverts was 38.5 weeks. The schedule for these works was set at 30.5

weeks. Something needed to be done. One of the first things that became apparent was that none of the resources were utilized to maximum capacity.

• Thus, with the help of insights and data collected from the Analyse phase of Six Sigma Methodology, changes were implemented, such as using the 14-ton Excavator

exclusively for lifting operations and using the BROKKs for the excavation instead! This improved efficiency significantly.

Six Sigma Innovation- Transforming a Victorian Tunnel for modern trains

Results

• By completing this Six Sigma PIP to reduce invert replacement cycle time prior to commencing site works at the Connaught Tunnel, the team mitigated quality,

schedule and budget risks.

•

In the end, the schedule was reduced by 13 weeks, including an additional five weeks against the project schedule. The additional five weeks were gained as a result of

the contractor engaging Yellow Belts to improve focused activities and remove more waste that was already included in the productivity assumptions.

• In addition, major risks were mitigated prior to starting work such as realizing that the 22-ton excavator would not perform the tasks as expected.

•

Not only did Six Sigma help identify and manage a schedule risk prior to starting works, it also reduced schedule by a further five weeks by promoting and

implementing continuous improvement.