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| FREQUENTLY
ASKED QUESTIONS |
| Lean
Six Sigma And Six Sigma
Consultation |
|
What
is Lean Six Sigma? How is
Lean Six Sigma different
from Six Sigma? |
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Traditionally, Six Sigma
focuses only on defect reduction
from a process which yields
only a marginal financial
benefits, where as Lean
Six Sigma combines the resource
productivity improvement
techniques with Six Sigma
to yield large financial
benefits. Lean Six Sigma
is the next level advancement
over "Classical Six
Sigma", to achieve
greater bottom-line results.
It is more effective than
Six Sigma which focuses
only on defect elimination
through process improvements.
Lean Six Sigma is ideal
for all service industries
and non manufacturing /
processes of manufacturing
industries. Lean Six Sigma
movement brings about tremendous
change in the working culture
of the organization.
Lean Six Sigma Trainings
shows how Lean and Six
Sigma methods complement
and reinforce each other.
Lean Six Sigma outlines
a program for combining
the synergies of both
the initiatives (the Lean
Concepts as well as traditionalSix
Sigma) to provide an organization
with greater speed, less
process variation, and
more bottom-line impact
than ever before.
| Lean
Six Sigma combines
the best of both Six
Sigma & Lean Systems |
| Differentiators |
Six
Sigma |
Lean
Systems |
| Approach |
Removes
variation [defects]
in process to improve
Quality |
Removes wastes (NVAs)
in process to improves
speed or velocity
|
| Method |
DMAIC, DMEDI, DMADV
The methodology is
more structured |
Kaizen, Kaikakku
(Rapid Kaizen) The
methodology is flexible |
| Focus |
Process Quality
|
Process Flow |
| Primary
Benefit |
Uniform Process
Quality |
Reduced Flow time |
| Secondary
Benefits |
- Less Variation
- Uniform Output
- Improved Quality
|
- Reduced Inventory
- Reduced Lead Time
- Reduced Waste |
|
|
Is
Lean Six Sigma and Six Sigma
applicable for service industries? |
| |
Yes! In fact it is more
applicable for service industries.
Any output whether tangible
or intangible could be measured.
In fact 90 % of the projects
in GE are related to service
outputs. Also, 70 % of SSA
Clients are from the Service
Industries. |
|
Can
I apply Lean/ Six Sigma
for a service outputs such
as Airline, Courier, Education
etc.? |
| |
Wherever defect identification
and opportunity for defect
is possible Lean Six Sigma
/ Six Sigma can be applied
with great ease. In fact
it is extremely simple to
apply for occasions like
baggage claim, parcel delivery,
ticket booking etc. |
|
We
are not ISO 9000 certified;
can we adopt Six Sigma movement? |
| |
Yes!
There is no connection
between ISO 9000 and Six
Sigma movement. There
is no sequence for implementing
both. ISO 9000 certification
is not a pre-requisite
for Six Sigma. |
|
Is
there a certification process
for Lean Six Sigma/ Six
Sigma for Organizations.? |
| |
No. It is not a contractual
standard like ISO 9000 for
which certification is possible. |
|
Will
I get any cost advantage
by adopting Lean Six Sigma/
Six Sigma? |
| |
Six Sigma projects contribute
to quality improvement and
customer satisfaction. Obviously
this will improve bottom
line and top line of the
business. |
|
What
way is Six Sigma approach
different from SPC? |
| |
SPC covers machine capability
/ process capability studies
to establish the Cp, Cpk
and helps to improve the
value by continuous improvement.
The assignable causes are
identified and removed one
after another. The control
charts are introduced to
control the process thereafter.
Whereas Six Sigma is a universal
metric which can be applied
to any situation with great
simplicity without any difficult
training and application
of mathematics. |
|
What
is the difference between
TQM and Six Sigma? |
| |
TQM is a movement whereby
a company can bring in quality
in everything it does, thereby
improve resource productivity
by elimination of waste.
Six Sigma is a measurement
tool which can help in measurement
of all departmental outputs
and drive continuous improvements
through problem solving. |
| Lean
Six Sigma And Six Sigma
Certification Trainings |
|
What
are the levels for Certification
in Lean Six Sigma/ Six Sigma? |
| |
There are 5 levels of
certification.
| 1. |
White Belt |
Preliminary
Levels |
| 2. |
Yellow Belt |
| 3. |
Green belt |
Specialized
Levels |
| 4. |
Black Belt |
| 5. |
Master Black Belt |
|
|
To
do a Black belt course do
I have to complete Green
Belt level? |
| |
For maximum effectiveness,
it is good if a candidate
has completed Green Belt,
though this is not mandatory.
If the participant has had
4-5 years of minimum industry
experience, and a few years
in 'Quality' (s)he can take
the Black Belt Programme
directly. The programme
is designed such that it
takes the candidate from
the very basics of 'Six
Sigma' or 'Lean Six Sigma'
to the specific, relevant
higher concepts. |
|
Can
a person- not in the management
team- also be a part of
the program? |
| |
It is advisable that people
in middle mgmt should be
nominated for the programme,
so as to meet the big picture
of the organization. |
|
What
is the feasibility of this
course and in which kind
of industries? |
| |
Lean Six Sigma is widely
applied for process improvement
and defect reduction and
as a strategy improvement
tool in many BPO's and service
industries SSA has consulted
companies such as ABN AMRO;
for institutionalizing Lean
Six Sigma. We have also
consulted HDFC, Taj Hotels
and many others who are
practicing lean six sigma
in a big way. The application
of Lean Six Sigma for BPO
& other Service industries
are different as compared
to the Manufacturing industries.
SSA has successfully implemented
Six Sigma concepts in various
Manufacturing industries
as well, like different
divisions of L & T,
Lipidata Systems, Godrej
Saralee and many others.
SSA uses iGrafx software
for process simulation techniques
for process improvements
in service industries. |
|
Is
Six Sigma Alchemy (P) Ltd
formally certified to give
these courses? / Has Six
Sigma Alchemy (P) Ltd an
association with any Accreditation
Body ( as with ISO Certifications)
that is qualified to certify
Lean/ Six Sigma Green Belts
& Black Belts?/ Is the
Certification from Six Sigma
Alchemy (P) Ltd Internationally
recognized? |
| |
The
concepts like Six Sigma
and Lean Six Sigma is
completely unlike the
other Certifications as
ISO, CMM-I etc. Unlike
the mentioned Certifications
that require an Accreditation
body to certify the Companies,
Six Sigma & Lean Six
Sigma requires no specific
Accreditation Body. In
fact, it is a myth to
associate these concepts
with any Accreditation
Body! There is no such
'Body' in the world for
certification of Six Sigma
Green/Black Belts. There
are only individual organizations
like SSA that qualify
professionals as Six Sigma/
Lean Six Sigma Certified.
Hence it is very important
to assess the track record
of the Organizations while
selecting them for a course.
The
following points make
SSA Certifications in
Lean Six Sigma at par
with the best World wide:
|
|
What
kind of a project do I have
to do for all Certification
levels? |
| |
Only Green belt &
Black belt trainings require
a project to be undertaken.
For Green Belt participants
will be working on a Project
Case developed by SSA. This
Project Case was earlier
a live project handled by
SSA Consultation Team, and
has been converted to a
Case to facilitate the participants
to apply the theory to practical.
It is mandatory for Black
Belt participants to work
on a live project. |
|
What
are the criteria for the
Lean / Six Sigma Certification
courses? |
| |
Following
are the mandatory criteria:
|
| ISO
9000 Quality Management
System |
|
Who
Compiled the ISO Standard? |
| |
Technical Committee TC176
represented by 70 country
experts compiled the ISO
9000 standard |
|
What
is one single motive of
adopting ISO 9000 standard? |
| |
To achieve customer satisfaction
consistently through validated
and standardized business
processes. |
|
Is
the ISO standard written
Industry wise? |
| |
No. The standard calls
for generic quality system
elements and professional
management practices to
be adopted when contractually
agreed with the certification
agency. |
|
What
is the validity of certification? |
| |
3 years is the validity
of the certification. Every
Six months there is a Surveillance
audit carried out by the
certification agency. Re
certification audit will
be done after 3 years. |
|
Which
ISO Standard is applicable
for our industry? |
| |
ISO 9001: 2000 is the
only contractual standard
against which all industry
QMS assessments are made. |
|
What
are the other international
standards one needs to be
familiar with? |
| |
ISO 9004-2000 for Total
Quality Management practices. |
|
How
it is adapted for various
industries? |
| |
- First, the scope and
purpose of the business
operation to be certified
is identified.
- The permissible exclusions
are decided for Product
Realization clause.
- The relevance of each
ISO 9000 clause’s
requirements are tailored
to the business processes.
- The Quality Management
System is built around the
business processes.
- The QMS manuals are prepared
to define the system adapted
with SOP’s. |
|
What
is verified by the certification
agency before certification? |
| |
- The scope of the business
to satisfy its customer
– clarity in deliverables
contractually agreed with
the customer.
- The coverage of the business
processes under the QMS
which will affect customer
satisfaction.
- The extent to which ISO
9000 standard’s elements
are addressed in the Quality
manual.
- The compliance of the
Quality system elements
in actual practice. |
|
What
are the benefits of ISO
9001:2000 standard? |
| |
- System in par with international
standard.
- Consistency in Product/Service
Quality.
- Customer concerned culture
in the company.
- Waste elimination &
hence cost control.
- Continuous Improvement
in product & service.
- Market Leadership through
Quality.
- Perpetuity of the Organization
due to customer confidence. |
|
What
is ISO/TS16949:2002? |
| |
ISO/TS16949:2002 is an
ISO Technical Specification
which aligns existing US,
German, French and Italian
automotive quality system
standards within the global
automotive industry. ISO/TS16949:2002
specifies the quality system
requirements for the application
of ISO 9001:2000 for automotive
production and relevant
service part organizations.
|
|
Who
are the authors of ISO/TS16949:2002? |
| |
ISO/TS16949 was prepared
by the International Automotive
Task Force (IATF) and Japan
Automobile Manufacturers
Association Inc. (JAMA).
The IATF consists of an
international group of vehicle
manufacturers, BMW Group,
Daimler Chrysler, Fiat Auto,
Ford Motor Company, General
Motors Corporation, PSA
Peugeot-Citroen, Renault
SA and Volkswagen, Plus
National Trade Associations,
AIAG (America), VDA (Germany),
SMMT (UK), ANFIA (Italy)
and FIEV (France). |
|
What
is the scope of the ISO/TS16949:2002
standard? |
| |
-ISO/TS16949:2002 in conjunction
with ISO 9001:2000, defines
the quality management system
requirements for the design
and development, production
and, when relevant, installation
and service of automotive
- related products.
-It is applicable to sites
of the organization where
customer - specified parts,
for production and / or
service, are manufactured.
-Supporting functions, whether
on-site or remote (such
as design centres, corporate
headquarters and distribution
centres), form part of the
site audit as they support
the site, but cannot obtain
stand-alone certification
to ISO/TS16949:2002 standard.
-ISO/TS16949:2002 can be
applied throughout the automotive
supply chain. |
|
Will
ISO/TS16949 be accepted
in addition to current automotive
standards such as QS-9000
and VDA 6.1? |
| |
Yes. Along with customer
specific requirements, ISO/TS16949
has been accepted as equivalent
to the following automotive
quality standards:
- QS-9000 (America)
- VDA 6.1 (Germany)
- AVSQ (Italy)
- EAQF (France) |
|
Will
current automotive quality
standards be replaced by
ISO/TS16949? |
| |
QS-9000 standard validity
expires on 14th December
2006 and ISO/TS16949:1999
standard validity expires
on 15th December 2003. The
second edition of ISO/TS
16949 cancels and replaces
the first edition (ISO/TS
16949:1999), which has been
technically revised. |
|
Are
any Changes required to
QS-9000 Certificates? |
| |
Certificates for QS-9000
will require amendment to
be valid past 15th December
2003. IASG Sanctioned Interpretation
issued on this subject will
be effective from July 1st
2002. All new certificates
from 1st July 2002 will
be issued containing new
wording. All existing certificates
will be reissued before
15th December 2003 to include
the new wording.
New certificates for QS-9000
can continue to be issued
throughout the extended
period, but must be transferred
over to ISO/TS16949 by 14th
December 2006. Again QS-9000
will cease to exist on 15th
December 2006 |
|
What
is CMM? |
| |
CMM stands for Capability
Maturity Model. It is a
frame work that describes
the key elements of an effective
Software Development and
Maintenance Process. |
|
Why
is CMM to be adopted? |
| |
Software development being
a complex process, there
is a possibility for customer
dis-satisfaction. There
is a need for improved software
process capability that
will guide organizations
throughout the software
development lifecycle resulting
in high quality software
product. |
|
Who
developed CMM? |
| |
Department of Defense
(DoD) of U.S , wanted to
evaluate more effectively
an organization's capability
to perform successfully
on software engineering
contracts. Prime contractors
wanted to evaluate the capability
of potential subcontractors.
To help organizations and
customers like the DoD and
prime contractors, Software
Engineering Institute(SEI)
with the Assistance of MITRE
Corporation has developed
CMM for software industries
and Version 1.0 was released
in August 1991 |
|
What are the applications
of CMM? |
| |
The CMM can be used in:
- Software Process Improvement
- Software Process Assessment
- Software Capability Evaluation
|
|
What
are the Definition of the
CMM Maturity Levels? |
| |
Level 1 - Initial level
At the Initial Level,
the organization typically
does not provide a stable
environment for developing
and maintaining software.
Level 2 - The Repeatable
Level
At the Repeatable Level,
policies for managing
a software project and
procedures to implement
those policies are established.
Level 3 - The Defined
Level
At the Defined Level,
the standard process for
developing and maintaining
software across the organization
is documented, including
both software engineering
and management processes.
Level 4 - The Managed
Level
At the Managed Level,
the organization sets
quantitative quality goals
for both software products
and processes.
Level 5 - The Optimizing
Level
At the Optimizing Level,
the entire organization
is focused on continuous
process improvement. The
organization has the means
to identify weaknesses
and strengthen the process
proactively, with the
goal of preventing the
occurrence of defects
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