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WELCOME TO SIX SIGMA DMAIC PROCESS PRESENTATION

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Rahul SagarM. Pharm IInd semPharmceutical-DRA

PRESENTED BY

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TQM

• Total Quality Management means that the organization's culture is defined by and supports the constant attainment of customer satisfaction through an integrated system of tools, techniques, and training. This involves the continuous improvement of organizational processes, resulting in high quality products and services.

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WHAT IS SIX SIGMA

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• Sig Sigma, the common measurement index is "defects-per-unit," where a unit can be virtually anything--- a component, piece of material, line of code, administrative form, time frame, distance, etc.

• The Sigma value indicates how often defects are likely to occur. The higher the sigma value, the less likely a process will produce defects. As sigma increases, costs go down, cycle time goes down, and customer satisfaction goes up.

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WHAT SO GREAT ABOUT SIX SIGMA?

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MENTOR

• Six sigma gives employees well defined roles & clear structures to their task

• Six sigma project are usually run by guys in the middle of the organization

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OPERATE IN MARKET PLACE IN TWO WAY’S

• Make more money by coming up with great invention, hiring away some real star

• Buying other companies

04/15/2023 9METHODOLOGY

DMAIC – The Improvement Methodology

Objective:DEFINE the

opportunity

Objective:MEASURE current performance

Objective:ANALYZE the root causes of problems

Objective:IMPROVE the process to eliminate root causes

Objective:CONTROL the process to sustain the gains.

Key Define Tools:• Cost of Poor

Quality (COPQ)• Voice of the

Stakeholder (VOS)

• Project Charter• As-Is Process

Map(s)• Primary Metric

(Y)

Key Measure Tools:

• Critical to Quality Requirements (CTQs)

• Sample Plan• Capability

Analysis• Failure Modes

and Effect Analysis (FMEA)

Key Analyze Tools:

• Histograms, Boxplots, Multi-Vari Charts, etc.

• Hypothesis Tests• Regression

Analysis

Key Improve Tools:

• Solution Selection Matrix

• To-Be Process Map(s)

Key Control Tools:

• Control Charts• Contingency

and/or Action Plan(s)

Define Measure Analyze Improve Control

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Define Define the problem.Define the customer(s) and the requirements.Define the current capability.Define the key processes that will have the greatest impact on customer.

Measure Identify the statistical measures to monitor the key process.Set up the data collection plan.Measure the process

Analyze Determine the analysis tools and methods to be used.Summarize the data measured.Run the analysis and determine the root causes, effects, etc.

Improve Improve and Implement.Focus on developing process/technology to improve the root cause.Test the method on sample process and validate the improvement.

Control Standardize and document the process and implement the plan.Monitor the process and feedback the results back to the process for continuous improvement.

DMAIC Methodology

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REWARDS OF SIX SIGMA

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• IMPROVED RELIABILITY & PREDUCTABILITY OF SOFTWARE PRODUCTS AND SERVICES

• INCRESED VALUE TO THE CUSTOMER AND SHAREHOLDERS• IMPROVEMENTS IN ORGANIZATIONAL MORALE• INCREASE MARKET VISIBILITY• ORGANIZATIONAL RECOGNITION• SIGNIFICANT REDUCTION IN DEFECT • INSTITUTIONALIZATION OF A “PROCESS” MINDSET

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Example of 6σ

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MUMBAI DABBAWALAS REDEFINE SIX SIGMA THEORY

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WHAT IS NMTBSA?

(Nutan Mumbai Tiffin Box Suppliers Association)

History : Started in 1880 Charitable trust : Registered in 1956 Avg. Literacy Rate : 8th Grade Schooling Total area coverage : 60 Kms Employee Strength : 5000 Number of Tiffin's : 2,00,000 Tiffin Boxes i.e 4,00,000 transactions every day. Time taken : 3 hrs

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WORKING OF NMTBSA

Error Rate : 1 in 16 million transactions•Six Sigma performance (99.999999)•Technological Backup : Nil.•Cost of service -Rs. 300/month ($ 6.00/month)•Standard price for all (Weight, Distance, Space)•Rs. 36 Cr. Turnover approx.•“No strike” record as each one a share holder •Earnings -5000 to 6000 p.m.•Diwali bonus: one month’s from customers.

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• Zero % fuel Zero % investment• Zero % modern technology Zero % Disputes• 99.9999% performance100 % Customer Satisfaction

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CODING SYSTEM

Initial Coding System used colored threads to mark 7 Islands

Then Utilized thrown away cotton waste from tailors

Now using color markers:

E :: Code for Dabbawala Street at residential stationVLP :: Residential Station Ville Parle3 :: Code for Destination station.9 :: Code for Dabbawala at Destination.Ex :: Express towers ( Building name)12 :: Floor no. in the building.

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JOURNEY OF DABBAWALA

Pick up Dabba from Residence/Caterer

and bring it to Andheri Station.

*Journey in Local Train*

Unloading and Sorting at

Destination Station.

Delivery to respective customers.

Collection of Empty Dabba.

Sorting at Destinations

station.

Returning Dabba to

Residence/Caterer.

9:30 A.M- 10:30 A.M 10:34- 11:20 A.M 11:20- 12:30 P:M

12:30 - 1:00 P.M 1:15- 2:30 P.M2:48- 3:30P:M

3:30- 4:40 P.M

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SIX SIGMA CERTIFICATION

In 1998, Forbes Global magazine conducted a quality assurance study on the Dabbawalas' operations

Gave Rating of 99.999999

Dabbawalas made one error in six million transactions.

Stood High along with MNC’s like Motorola, GE etc…

Dabbawalas got ISO 9001- 2000 for Excellence in service

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ACHIEVEMENTS

Documentaries made by : • BBC ,UTV, MTV, ZEE TV, AAJ TAK, TV TODAY,

SAHARA SAMAY, STAR TV, CNBC TV 18, CNN, SONY TV, TV TOKYO, NDTV.

CASE STUDY made by : • ICFAI Press Hyderabad & Bangalore• Richard Ivey School of Business – Canada• Also, Included in a subject in Graduate School of

Journalism University of California, Berkeley

Invitations from : • CII for conference held in Bangalore, IIML, IIMA, CII

Cochin, CII Delhi, Dr. Reddy’s Lab Foundation Hyderabad, SCMHRD Pune, SCMHRD Nasik, Sadahana – Pune, Rotary Club – Bangalore, NIQR at Chennai

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ACHIEVEMENTS

• World record in Best Time management.

• Name in “GUINESS BOOK of World Records”.

• Registered with Ripley's “ believe it or not”.

• Invited for marriage of Hon. Prince Charles of England on 9th April, 2005

• Documentary called “Dabbawalas, Mumbai's unique lunch service”

• by two Dutch filmmakers in 1998.

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LETTER FROM PRINCE CHARLES

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