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Niraj Goyal

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Case Study: Increase Revenue by Decreasing Prices

A division of a diversified organization develops and manufactures samples of new drugs for clinical trials. This work entails different typical manufacturing problems for the following reasons: Quantity requirements can vary from a few grams to several tons from order to order. The effort of research and development (R&D) is central; new processes have to…

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Case Study: Improving the Flow of Cargo and Documents in a Shipping Company – Part 1 of 2

In this case study, a team wants to be sure their customer-focused business is satisfying its clients. Part 1 focuses on reducing the wait times associated with transferring cargo and documents. Part 2 looks at making more improvements using just-in-time (JIT) principles. A 15-year-old shipping company with a network of offices throughout India considered being “value-driven, customer-focused”…

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Case Study: Improving Recruitment Processes – Part 2 of 2

In this case study, a team strives to improve the recruiting process in a large, fast-moving consumer goods company. Part 1 focused on reducing the recruiting cycle time. Part 2 focuses on decreasing the effort required to fill a job opening. The case described here uses total quality management (TQM) to address the problem of…

Case Study: Improving Recruitment Processes – Part 1 of 2

In this case study, a team strives to improve the recruiting process in a large, fast-moving consumer goods company. Part 1 focuses on reducing the recruiting cycle time. Part 2 focuses on decreasing the effort required to fill a job opening. Rising attrition is a common problem across industries. Tight monthly, quarterly and annual objectives…

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Case Study: Reducing Turnaround Time of Lab Reports in the ICU

A 250-bed hospital had implemented total quality management (TQM) to improve customer delight in its diagnostic clinics. After that success, the management team of the hospital was ready to proceed with further process improvement. After completing a brainstorming and prioritization exercise, the team determined to next address the problem: delay in receiving test reports for patients…

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A Supply Chain Case Study – Socks Manufacturing: Part 2 of 2

A socks manufacturing company in India turned to TQM to improve its supply chain. In Part One, the case study describes the process of elminating a significant cost for the company – delivery delays. This week, Part Two of the case study looks at the broadening of the application of process improvement beyond deliveries. The…

A Supply Chain Case Study – Socks Manufacturing: Part 1 of 2

A socks manufacturing company in India turned to TQM to improve its supply chain. In Part One, the case study elminates a significant cost for the company – delivery delays. Part Two of the case study looks at the broadening of the application of process improvement beyond deliveries. A fledgling socks manufacturing company in India was working to…

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Brewing a Better Beer with TQM

Recently, a well-established, rapidly expanding beer company invested heavily in a modern, state-of–the-art brewing facility. The new facility dramatically improved quality and productivity, and also reduced costs through the application of new technology. As a next step, the beer company began exploring methods of achieving a further quantum jump in performance. Recognizing that technology and…

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Fixing Payroll Problems: A TQM Case Study in Human Resources

A large, Indian, fast-moving consumer goods company had completed successful total quality management (TQM) projects to improve its manufacturing efficiency, expedite vendor payments and increase availability of finished products. For its next project, the company wanted to address problems in human resources (HR). By working with HR process owners, a focus for the project emerged…

Medical Transcription Six Sigma Case Study

Today’s industrial black belt typically trains for six months. Seventy-five percent of this training time is spent learning theory, and the balance is spent in practice. Often when the black belt returns to the real world to tackle inefficiencies, he finds that there are no takers for his logic and passion – his Six Sigma entreaties fall on…

Facilitation: A Critical Soft Skill For Success

Much has been written about the techniques and tools of Six Sigma. A large part of Black Belt training is focused on mastering the “hard” skills. Most case studies demonstrate the usefulness of tools or techniques. Any experienced, successful practitioner of Six Sigma will tell you that the soft skills of facilitating a group are…

Selecting Appropriate Metrics

A frequently asked question by Six Sigma practitioners is how to select appropriate metrics for a particular organization or process. Considerable material has been written on this subject. This paper focuses on three aspects that should be of interest to Six Sigma practitioners: Why are metrics – and more importantly appropriate metrics – needed? A five-step procedure…

Six Sigma Case Study: Converting Paper to Electronic Documents

This work described below was carried out in a large company based in the U.S. and India. The project dealt with converting printed paper from U.S. customers into electronic copies. The material was quite heterogeneous in nature – consisting of assorted magazines and legal papers. It is part of an ongoing operation that services several…

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Applying Lean Manufacturing to Six Sigma

There are continuing questions about the relationship between Lean manufacturing and Six Sigma techniques. This relationship has been expressed as follows: Stretch the process applying Lean techniques Solve the problems of deviation from the standards Ensure maintenance of the improved status using Six Sigma techniques However, if the system and processes are too poor, stretching…

Newspaper Aims to Improve Printing: A TQM Case Study

Caught in an exploding market, with rapidly improving products, the management of a media organization in India realized that improving the quality of printing of its newspaper was imperative to survival and progress. The organization adopted total quality management (TQM) and has completed several improvements in office processes related to turnaround, which is so vital…

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TQM Case Study: Ensuring On-time Newspaper Delivery

Newspapers face pressure from their external customers to minimize the cycle time of their production process at both ends of the supply chain. At the start of the chain, readers want the freshest news, while advertisers want the latest possible closing time for booking ads. At the end of the chain, even a few minutes…

TQM Case Study: Newspaper Focuses on Customer Service

Quality in the total quality management (TQM) method is defined as customer delight. Customers are delighted when their needs are met or exceeded. The needs of the customer are: Product quality Delivery quality Service quality Cost value Improving customer service was the focus of two projects within the deployment of TQM in a mid-sized newspaper…

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From Dojo to Office: Training Lessons from Martial Arts

Failed Six Sigma efforts often are attributed to ineffective training of Black Belts and Master Black Belts. But there is a more fundamental issue at hand: the training and experience requested of Black Belts. It may be time to reconsider the typical certification process in order to produce expert Belts and lower the odds of…

Sustaining Improvement by Building a Quality Mindset

A common problem encountered in Lean, Six Sigma and TQM implementation is performance deterioration after the completion and handover of a breakthrough improvement. This can happen despite installation of control mechanisms to monitor ongoing performance. In this case study, a financial services company with a national sales network had already begun addressing concerns about its…

Sustaining Breakthrough Improvements in Insurance FirmAn iSixSigma Case Study

A young, rapidly expanding insurance company in India, which was looking for breakthrough improvements in its customer service, decided its No. 1 critical-to-quality objective would be “reducing the turnaround time from an insurance proposal to policy.” Phase 1 of the project achieved dramatic success with turnarounds, reducing time in the central processing division by 80…

Reducing IT User Downtime Using TQM – A Case Study

This Information Technology (IT) case study was done during the implementation of total quality management (TQM) in a financial services company with several hundred computers and computer users in multiple locations throughout India. The results have widespread applicability and in particular are aimed at organizations with large computer networks, IT facilities management companies and customer…

Improving Financial Services Through TQM: A Case Study

The work described in this case study was undertaken in a young, rapidly expanding company in the financial services sector with no previous experience with total quality management (TQM). The quality project began with a two-day introductory awareness program covering concepts, cases, implementation strategies and imperatives of TQM. The program was conducted for the senior…

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