kpmg lean six sigma offerings_iim_ranchi

Draft Approach for Lean Six Sigma Green Belt Competency Development Program atIndian Institute of Management,Ranchi

29th June, 2015

Setting the ContextEstablishing the need for Six-Sigma Programs in organizations

3 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.

Six Sigma Drivers and LeversHow do we answer the key questions?

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Target Customer SegmentsVoice of customer

Analyst views

Purpose, Vision, Values, Goals

Input from business development

Competitive environment

Brand study

Financial Benefits

Revenue GrowthMargin Enhancement

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Service Benchmark

Quantitative Insight

Change management Strategy

Process Capability

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Quantified performance measurement

Growth Opportunity & career Progression

Compelling Purpose, Vision and Goal


Six Sigma DriversHow do we answer the key questions?

Six Sigma is a set of strategies, techniques, and tools for process improvement. It was developed by Motorola in 1981.Six Sigma is a management methodology meant for driving process improvements in the delivery of goods andservices. It provides businesses with the tools to improve the capability of their business processes. The increase inperformance and decrease in process variation leads to defect reduction and vast improvement in profits, employeemorale and quality of product.

Six Sigma certification is similar to other professional courses in that after having cleared specified guidelines andfollowed the required procedure, individuals are certified as capable of employing the gained knowledge in theirrespective field. There are several stages of the program and with each qualifying level, certain tests that have to becleared. There are various belts such as green belt, black belt and master black belt awarded to professionals whocomplete corresponding stages of the course.

KPMG in India has developed a balanced program, specific to the needs of professionals, that allows yourtransformation into an effective change agent, who can, using the Six Sigma framework bring about significantimprovements in the organizations performance. Six Sigma Green Belt Course for Business Excellence is a four-daycomprehensive session to provide a firsthand experience of the nuances of Six Sigma. The training program wouldrevolve around the key concepts, the process of implementation and the specific challenges. The program also teachesthe basic statistical tools and techniques used in Six Sigma. The four days of Green Belt training will be conducted onthe various phases of DMAIC model to enable the Green Belts to work in terms of methodology, tools & techniques.

Six Sigma is an Industry Independent methodology and has been successfully applied across: Manufacturing Industry including Automotive, Aero Space, Health Equipment, FMCG, Electronic Goods, Continuous

Process Industry, Textiles etc. Service Industry including Telecom, Banking and Financial Services, Health Care, Insurance, Hotels, IT, ITES, KPOs,

Airlines, Cargo Movement, Support Services, HR Services, Marketing Services etc. R&D organizations or in R&D functions of various organizations


Six Sigma: Domain wide Applications

Human Resource FinanceMarketing

OperationsInformationTechnology Logistics

Improve on-time delivery of products to customers

Improve on-time delivery of goods to our facility from vendors

Improve documentation accuracy Reduce line downtime due to

shipping/receiving Improve inventory control/rotation Improve inspection processes Reduce the space occupied by the

inventory

Increasing the effectiveness of the process

Optimizing the Sales cycle Improving the cost utilization Procurement time reduction and

optimization Reducing the defects in the process

flow Reduction in inventory system Waste reduction in internal

processes

Increasing customer engagement Reducing the overall Software

development times Improving the estimation process to

reduce time and cost overruns Improving the requirements

gathering process to reduce rework Reducing complaints resolution time Creating systems to detect defects

early in the process

Increasing customer engagement Reducing the overall Software

development times Improving the estimation process to

reduce time and cost overruns Improving the requirements

gathering process to reduce rework Reducing complaints resolution time Creating systems to detect defects

early in the process

Reduction in iteration rate of the employees

Training need assessment Improving the skill matrix for

employees Reduction in hiring time and

optimizing productive time Leave management system

optimization Optimum workforce management Reducing Mind to market cycle time

Turnaround time reduction of the customers

Error proofing of the system Optimizing product

disbursement time Reducing the Working Capital

and Financial requirements Developing new financial

products Optimizing procure to cash

cycle


Six Sigma: Major Industry wide Applications

IT ServicesCreating systems to detect defects early in the

process (to reduce high costs associated with defects identified later)

Reducing appraisal cost per defect by phase and appraisal type (by project and in total)

Reducing reworkImproving the requirements gathering process

to reduce rework Reducing complaints resolution time

BankingReducing the Working Capital and

Financial requirementsDeveloping new financial productsOptimizing procure to cash cycleTurnaround time reduction of the

customersIncreasing sales productivity

FMCG Improving overall Yield of each shift Reduce scrap or spilled materials Reduce the Process failures or breakdowns Increase Plant capacity utilization Optimizing the Sales cycle Procurement time reduction and

optimization Reducing the defects in the process flow Reduction in inventory system

RetailEliminating manufacturing errors/defectsImproving first sample approval percentages

while working with buyersImproving buyer satisfaction levels Increasing repeat businessImproving supplier evaluation processesImproving processes at the source to reduce

rejections at later stagesReducing costs and delays

ManufacturingReduce Manufacturing cycle timeImprove Customer Service performance scoresReduce or optimize inventory levelsReduce cost of poor quality & warranty costReduce rejections due to design errorsImprove parts design process to meet

specificationsImprove parts reliability by identifying &

optimizing critical factors that ensure reliability

R&D/TechnologyReducing rework through synergy between R&D

and the customer facing staffImproving the overall performance & qualityMinimizing product failures by ensuring robust

designs and savings on warranty costImproving quality of research process &

experiments by providing mass education in Experimental design

Improving quality of design reviews

Course OverviewScope of the engagement


Six-Sigma Green Belt Course - Overview

Six Sigma Green Belt Course for Business Excellence is a four-day comprehensive session to provide a first hand experience of the nuances of Six Sigma.

The workshop would revolve around the key concepts, the process of implementation and the specific challenges. The program also teaches the basic statistical tools and techniques used in Six Sigma.

Green Belts are an integral part of the Six Sigma methodology requiring sufficient training to support Six Sigma implementation. They are also qualified to lead certain Six Sigma improvement projects.

The four days of Green Belt training will be conducted on the various phases of DMAIC model to enable the Green Belts to work in terms of methodology, tools & techniques.


Course Contents

DefineDefineCustomer Expectations of the process?

Understand Six Sigma Project definition and Charter High level Process Mapping COPIS

MeasureMeasureWhat is the frequency of defects?

Critical to Quality (CTQ) Characteristics Learning and usage of tools like FMEA, Cause and Effect diagram, Pareto and detailed process mapping

Performance standards MSA - Gage R&R, Attribute Agreement Analysis

AnalyzeWhy, Where & When do defects occur?

Graphical Analysis Process Capability Cp, Cpk, Zst and Zlt Identify variation sources Hypothesis testing ANOVA, Chi Square, 1-sample t, 2-sample t, 1-proportion, 2-

proportion, Regression Analysis

ImproveHow can we fix the Process?

Brainstorming techniques and TRIZ Solution Selection, error proofing - FMEA Pilot Improvement plans Deployment Cost Benefit Analysis

ControlHow can we keep the process fixed?

Control Charts Variable and Attribute Charts Implement Process control Project closure

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Why KPMGHighlighting our capabilities to deliver this service


Business Excellence Practice: Overview

Service line/Solution Overview:About the service line/solution, FTE, etc. National resource pool of 15

consultants with average industry experience of 12 years. These include: Master Black Belts Black Belts Green Belt practitioners

Industry: Energy, retail, FMCG, utilities, port, hospitals, IT/ITES, government, Airport and others

More than 35,000 hours of services delivered to various clients

Standard methodologies and communication strategies to operationalise onshore-offshore delivery

Executed multiple projects leading to EBITDA, Margin, G&A and other cost improvements via Lean, Six Sigma, IE , TPM implementations

In Analytics domain: 7 Step approach from Problem to

Decisions; Focus on areas like Workforce

Management, Sales & Marketing etc.

Expertise in tools like R Technology Partnerships on the

anvil

Practice Overview

Service Offerings

Lean Six Sigma Advisory Facilitation Based Projects Full Scale Implementation

These may include TPM and specific Industrial Engineering projects as required.

Data Science Advisory 7 Step approach from Problem to Decisions;

Lean Six Sigma Training Lean Six Sigma Green Belt Lean Six Sigma Black Belt Training Lean Six Sigma Advanced Programs

Approach linking Data Science to Business Process Improvement using Lean Six Sigma

Key Differentiators

Experience in diverse industries like Manufacturing, FMCG, Retail, IT & ITES, Financial Operations, Clinical Research , ports, airports and Consumer Appliances

Solution mix of Lean, Six Sigma, TPM, and specific IE methodologies

First among the Big 4 to have Six Sigma Practice in India

Trained more than 14,000 participants on Six Sigma globally. Now approx. 200 per month

Adani Group Philips British Telecom SunTech

Key clients

Large and Mid market companies enrolled for KPMG Green & Black Belt Training

Black Belt Projects handled spanning diverse industries

Dedicated team of Six Sigma resources including Master Black Belts and Black Belts

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Matrix Cellular Oracle Madura Fashion Lifestyle Delhi Technological University

Reuters Symbiosis Institute of Operations Mgmt IITs IIMs


Some Of Our Associations


Voice of Customer

The training in 6 Sigma methodology helped me plan very efficiently, a project currently on in my organization. The project is expected to help my organization immensly. The training changed the way I looked at such projects and I believe our team has achieved much more than what it would have without six sigma methodology

- Girish Raja, Six Sigma Public Program Participant, Pune

Hi Nitesh,The six sigma program with KPMG has helped me improve my understanding on the concepts of Process Improvement to a great length.Also, at my organization we have taken the initiative to train people and create a forum that is trying to adapt the Six Sigma principles as per our organization process and policies

- Priyanka Grover, Six Sigma Public Program Participant, Mumbai

I had attended the Six Sigma - Green Belt session in November 2007 and my overall learning experience has been very fruitful. The methodology (across industry examples) used to deliver the session has helped me to re-align my thought process and that has clearly reflected in the quality of my work... I was able to drive many process re-engineering project which have lead to dollar and manpower saves. Also now I am actively involved in global projects.

- Ketan B Kurani, Six Sigma Public Program Participant

Dear Sir,The project details are as follows:...Achievement:Cpk improved from 0.28 to 0.95.The sigma level improved from 2 to 4.1 sigma.Potential Savings after the improvement amounted to Rs.17304480 per annum.

- Nitu Sharma, Student Symbiosis Institute, Nasik

The course material is well structured & with proper guidance with well suited examples from all fields( manufacturing, software solutions, ITES etc.). Therefore a practical scenario was established during the courseit helped me in interview a lot since questions were asked about several quality & statistical tools & there significances

- Prashant Pareek, MBA Student, Symbiosis Nasik

Thanks for your guidance and support..training was really meaningful and fruitful for my career perspective. I have implemented the methodology in few of my company projects and achieved the unexpected results.One of my projects was At the end of the projects we were able to save plenty of time in entire cycle

- Alok Tripathy, Six Sigma Participant, Delhi

Commercial


Commercials

Note: This fee does not include additional expenses such as food for the faculty, copying / duplication of training material, shipping charges, as applicable. The same will be charged on actual. KPMG will provide one hardcopy of training material prior to commencement of batch. Rest may be photocopied, as appropriate by your Institute. It will be our endeavor to keep the other expenses as reasonable as possible.

We are keen on continuing our relationship with Indian Institute of Management, Ranchi and value this opportunity to be of assistance. Considering our relationship and the time and effort for the program, we propose the following professional fees.

# Theme Activities Fees Notes

1 Lean Six Sigma

Green Belt

Training,

Evaluation and

certification

Kick off, Pre-Program Preparation and Organizational Understanding

Green Belt Program (4 days)

Training - INR 8,500/- per student (inclusive of all applicable taxes)

Considering

minimum of 40

students undergoing

this program.


Sample Certificate

Contact Details

in.kpmg.com

The information contained herein is of a general nature and is not intended to address the circumstances of any particular individual or entity. Although we endeavor to provide accurate and timely information, there can be no guarantee that such information is accurate as of the date it is received or that it will continue to be accurate in the future. No one should act on such information without appropriate professional advice after a thorough examination of the particular situation.

2015 KPMG, an Indian Partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (KPMG International), a Swiss entity. All rights reserved.

kpmg lean six sigma offerings_iim_ranchi

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