Sambit Dash
Six Sigma @60 Min
2023
Gateway to Success
A little about Me
Some of the Books I love
My Youtube Channel :
+8106967289
Ximb.Sambit@gmail.com
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John owns a small manufacturing unit, turnover ~ $ 500K which has 100+ employees working on it,
he heads all functions sales, marketing, operations, manufacturing, services etc. However he does
have people under him to help him out.
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John Has a Simple Way of working, Comes to office :
• Any pressing needs which needs immediate attention
• What are the sales & order status
• Production plan & Delivery forecast
• Procurements, Finance payouts
• And may more in day to day, Few more areas on monthly, quarterly, Yearly.
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8.5
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Month wise issues John has
resolved in last 12 Months
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Manufacturing
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Sigma _ Sambit
Jan-21
Feb-21
Mar-21
Apr-21
May-21
Proccurement
Jun-21
Jul-21
Aug-21
Warehousing
Sep-21
Oct-21
Storage
Transportation
Inventory
Customer
Supplier
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Is this the Correct way ?
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The “ Fire Bridget” Syndrome
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What is Six sigma ?
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ANY ORGANISATIONS
Services
Manufacturing
Anything Else
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Why Do they Exist ?
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Why Organisations Exists ?
To serve
Customers
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And Make them
happy
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HOW ?
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Organisations
Processes
Sub processes & Tasks
Raw material procurement
Storage / Warehouse Process
Assembly line
Sub assembly line
Core manufacturing process
Packaging
Logistics
Quality control & quality
assurance
And many more
Organisations produces its product or Services Through its processes
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Organisations
Processes
Sub processes & Tasks
Defects or Issues or
customer complaints
Raw material procurement
Storage / Warehouse Process
Assembly line
Sub assembly line
Core manufacturing process
Packaging
Logistics
Quality control & quality
assurance
And many more
Few of this Sub process or task goes wrong & result is you have a defective
product
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What is Six sigma ?
Six Sigma is a method that provides organizations tools to improve the capability of their business
processes. This increase in performance and decrease in process variation helps lead to defect
reduction and improvement in profits, employee morale, and quality of products or services and most
importantly customer satisfaction
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The Lean Six Sigma Concept
The lean concept of management focuses on the reduction and elimination of eight kinds of waste known as DOWNTIME,
an acronym formed by the words defects, overproduction, waiting, non-utilized talent, transportation, inventory, motion,
and extra-processing. Lean refers to any method, measure, or tool that helps in the identification and elimination of
waste.
The term Six Sigma refers to tools and techniques that are used to improve manufacturing processes. The strategy
attempts to identify and eliminate the causes of defects and variations in business and manufacturing processes.
Six Sigma's DMAIC phases are utilized in Lean Six Sigma. The acronym stands for define, measure, analyze, improve, and
control. It refers to the data-driven five-step method for improving, optimizing, and stabilizing business and
manufacturing processes.
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This is how a six sigma project is executed
+
700 + Tools are used to ensure data driven decision making
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Organisational Goals
Customer Requirements
Organisation Problems
Areas which should be used as projects
PROJECTS With DMAIC
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Benefits
• Ensures data driven decision making which helps to remove any assumptions or pre-judice
• Lean Six Sigma seeks to improve employee and company performance by eliminating the
waste of resources and process/product defects.
• It combines the process improvement methods of Six Sigma and lean enterprise.
• Lean Six Sigma helps to establish a clear path to achieving improvement objectives.
• The Lean strategy was established by Toyota in the 1940s and attempts to streamline
operational processes, from manufacturing to transactions.
• Six Sigma originated in the 1980s and seeks to improve output quality by reducing defects.
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Lets go back to John and understand what he should have done
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John Has a Simple Way of working, Comes to office :
• Any pressing needs which needs immediate attention
• What are the sales & order status
• Production plan & Delivery forecast
• Procurements, Finance payouts
• And may more in day to day, Few more areas on monthly, quarterly, Yearly.
Always
firefighting
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Immediate
requirement is met.
Root cause is not
identified
The problem comes
back after few time
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Sub processes & Tasks
Defects or Issues or
customer complaints
Projects
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Warehouse process
All Problems & Ideas for Improvement
Prioritisation & Filter
Projects
Imbalanced
priorities
Overstocking
of inventory
Inefficient
product labeling
Poor
warehouse
layout
Substandard
housekeeping
Lack of employee
training
Poor safety
management
Failing to
automate
Failure to measure
performance
Biggest benefit of using this structure is that this problems will be solved once for all and will not occur again
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Annexure
Performance How efficient or effective your warehouse is
Resources
Any thing necessary to accomplish a task or a
larger Goal
Method
A way of doing something
Quality
The standard of something as measured against
other things of a similar kind
Value
Importance, worth, or usefulness of something
Defects
Anything less than the customer (Can also be
process, stakeholder etc) wants
Waste
Any action which doesn’t add Value
Variation
Inconsistencies
Process improvement
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Improving efficiency or effectiveness
of your process
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Thank You
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