[Vinay]

Hi Matt,
Is it possible to send Visual basic program for calculating Cpk using Excel.
thanks
 
vinay
 

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[Vinay]

Thanks Vivek,
Your reply says it all.
Vinay
 

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[Vinay]

Thanks a TON Andy,
Its done now, did much of research and work on Net and came to lot of information. Thanks again.
Vinay
 

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[Vinay]

Thanks Anand,
Would wait for your reply.
 
Regards,
Vinay
 

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[Vinay]

Thanks Anand for this reply and information. One more thing, there is some clause which is not applicable to the service industry (BPO), as I am not able to confirm the same from anywhere, please let me know that. I am not able to find the same from Internet as somewhere it talks about the clause 7 in which i.e.design and development of the product.
This confusion is still with me.
Regards,
Vinay
 
 

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[Vinay]

Hi
I am working at BPO TRANSPORTransport insustry here time is everything for us i have so many ideas but i would like to go through the six sigma  

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[Vinay]

 am in problem regarding FMEA, please any body help me ?

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[Vinay]

support meaning providing technical assistance to clients in which process are not defined properly…

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[Vinay]

support meaning providing technical assistance to clients in which process are not defined properly…

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[Vinay]

Hi
Do u have any idea how could it b applied to a support kind of project…?

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[Vinay]

yeah..i got the jist..
well but are reluctant to change..
there are certain set who dont want to get adopted to it…even after knowing its effectiveness….
so i am trying hard on it….
after convincing the pool about its gud effects…what should be the first step…..which model to be followed..and what is the approximate time it should take to get implemented…?Thx a lot..
Vinay

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[Vinay]

Well, i am very new to this field,actually just got into the industry after doing post graduation… though i have studied about six sigma theoretically…its not looking easy right now..
can i get some suggestions to implement this process in IT organization which is not very big..
its a growing organization where people are very eager to learn.Vinay

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[Vinay]

Hi,
Please send copy of 8 D form.
thanks you very much.
Vinay
 

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[Vinay]

Thanks for your e-mail. I have studied statistics at college level but never heard about Sig-Ma. I very much agree with everything you explained in your response but I am still confused about Sig-Ma. I tried to search on the internet using word “Sig-Ma” but I could not find anything.

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[Vinay]

Completed several hundred small and large six sigma projects in electronics manufacturing environment. ASQ SSBB Certified.

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[Vinay]

There are several benefits:
(a) Employees can have longer breaks, (b) In case there is an increase in demand or rework, and company does not need to pay overtime, (c) If an employee is on vacation or need some time off, other 4 employees can produce more to compensate for the missing employee.
 
    

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[Vinay]

No. You are looking at this the wrong way. One’s aim should be to reduce sigma (standard deviation) to minimize probability of any reading falling outside the Upper and Lower specification limits. Larger the standard deviation (sigma) more changes of process data falling outside the specification limits.
  
 
 

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[Vinay]

Cpk is inversely proporational to Sigma. As sigma (standard deviation ) decreases, Cpk value increases.
Cpk = Smaller of (USL-Mean), (Mean – LSL) / 3 sigma (standard deviation)

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[Vinay]

“I don’t believe you need to be certified to use 6-Sigma.” – I agree with you. 
“My company has sent a few people to be trained and certified by high cost consultants only to leave shortly there after”. – so what is wrong with that? It means they have more marketability after certifications. 
“We switched and began to hire BBs that were already certified and they were not very effective.” – In order to be very effective, you need to understand the processes. To any new employee, it takes time to get familiar with the people and the processes. You are not saying they were not effective.
 
There are lots of engineers those who do have a formal engineering degree but only handful are doing well. You can easily differentiate who are degreed and who are OJT engineers. Nothing against OJT engineers but if you give something new to a degreed engineer, even something he has not done it in the past, will figure it out. On the other hand, OJT engineer will be hesitant to take the new assignment and will take a long time. 
 
One day when you get certified, you will appreciate the value and the distinction that comes with it. 
 

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[Vinay]

What do you think, is it really sick based on your experience? I think this is one of the finest tool to recognize and address any process improvement opportunity. Think positive….There is always room for improvement.

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[Vinay]

I agree with you that posts like “what does Six Sigma mean?” and “is there anybody in my city that trains Six Sigma?” are not some of the very smart questions but keep in mind…no question is a stupid question. If you take this kind of approach, you cannot run a six sigma project. People from other functional areas are going ask stupid questions but that does not mean that we should discourage them to raise their concerns. As a BB or MBB, you should be ready to handle this kind of questions. I have met so many CEOs and Sr.VPs asking some of the most stupid questions.  
If you do not like this kind of posting, just ignore it. I hope you are from the US and understand very well that in democracy people have rights to say whatever they want, like you have expressed your opinion.   

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[Vinay]

Japanese companies do not use buzz words they make good things as a part of their day today life. I used to work for Panasonic in India before coming to the US. We used to collect data and analyze on daily, weekly, monthly and yearly basis but never used to call it SPC. When I came to the US, one of key requirement to get a job was to know SPC.
I am pretty sure Japanese companies use BBSS methodology but probably they do not publicize it as much as any US company.

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[Vinay]

I am sorry to hear your bad experiences. However, I have worked for many companies and I was able to make my place in a very short. Whatever I am today is becuase of six sigma. This is one of the finest and most productive program I have seen in my life time. 
  

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[Vinay]

First of all if you have successfully implemented ISO program that means you have a consistent and repeatable process. Let me recommend you to start backwards. What are your top 3 CTQ problems after they left your facility? Trace it back to prevent any reoccurence and take the human factor out and make the process Poke-Yoka.
It seems you are in some sort of manufacturing business?    

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[Vinay]

It depends on the project complexity. Also, you do not have to apply all the tools available to you, you apply whatever is necessary or deemed necessary. There is no one formula. Something worked for one company may or may not work for other. In my experience mapping your process using flow chart the process you want to improve is a great way to start. Fish bone diagram is another good tool.

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[Vinay]

Sigma provides bunch of tools – use whatever applies and works for you in improving your processes. Anytime you talk about a room for improvement (which is everywhere), you can apply six sigma methodology.
In fact we apply six sigma tools in our day today life. We try to make the best decisions based on our knowledge and take appropriate corrective actions to make it better next time.   

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[Vinay]

No you do not need a certification but once you are certified, you get more respect and recognition in the company than your peers.You get more opportunity for growth by having bigger exposure to other cross functional activities and thus make your ideas and your self more visibile. If you have the potential, sky is the limit afterwards. – my two cents

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[Vinay]

Very interesting question.
If it is a new concept then use “common sense” what is more critical to end users. You have nothing to compare with. If it makes someone’s life easier, better and improves efficiency then it would be successful.

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[Vinay]

I was reading some where TQM on steroids + Lean = Six Sigma.
This is my understanding about six sigma – You start looking into a bigger picture from the top management’s point of view than looking from the middle managments point of view. You use the tools how to present and sell your ideas that is easily understandable by the top management.

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[Vinay]

Are you proposing to have a separate forum for each country? This is not a six sigma process. English is an important international language but if Japanese products are considered no 1 in quality, it is not because of English, if Germans machineries are one of the finest in the world, it is not because of English.
I understand your that sometimes it is hard to understand others point of views but at least they are trying their honest efforts in a language that is not their native language. We should not only appreciate their efforts but encourage their participation.
Six sigma approach is to include everyone one and their idea not to exclude anyone.  

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[Vinay]

Well, we had supplier in the US, Mexico and in Asia Pacific. The time we cut down was from a domestic supplier. However, I was managing over 20 contract manufactuers in Asia and most of the time they were delivering products and services on time.
Keep in mind anything is achievable as long as a customer we do not set unrealistic expectations. Most of the time Contract manufactuers are more flexible and responsive to your requests than your own in house people.
 

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[Vinay]

“Last time he was bright and hardworking person”. – Are you saying that he used to be a bright and hard working person?
“After promotion he was transferred to another dept.” – Was he transferred to your department after promotion?  Or he was transferred to another department than the one he was originally hired?
“Because he is not very familiar with the internal procedures and work environment, he tends to make mistakes every now and then.”- Well it seems (a) either he did not get proper training, (b) He is unable to handle this job or does not like it.  
“He gets upset whenever a mistake is made” – well we all make few mistakes and do not want to hear from others. As I mentioned earlier 99.9% people by nature take lot of pride in their work and feel bad when they make mistakes. We all do not like any finger pointing towards us, we immediately go in the defensive mode, stop listening and come-up with excuses to cover our mistakes. Let him realize, and come forward with his own corrective actions instead of excuses.
How to setting work objective and encouraging him.- Let him feel comfortable in discussing his weakness and strengths with you. Provide him help/training as needed. Recognize him everytime he does a good work. Encourage him that he can do much better.
I hope it would work for you. It worked for me. As I said except few bad examples (.1%), I was pretty successful in getting more than expected performance from the people reporting to me.
 

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[Vinay]

Very true. There should be a course on “Common Sense” which is not common.

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[Vinay]

People are having a hard time to meet 6 sigma target…six sigma is not the end of it….there is always room for further improvement

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[Vinay]

About 1000-1500 people reported to me last the 26 years.
In 99.9% cases this situation is controllable. In 0.1% nothing you cannot do about it and the only option is either transfer him/her to an area where he/she can do a better job. If he/she has an attitude problem then last option is to write him/her and follow the the HR process to fire him/her.
I strongly believe that a good Manager is the one who can get the best out of his people. Keep in mind you cannot treat everyone with the same stick. You have to learn how to deal with each individual, some people understand good language and some people do not. 
In order to make more recommendations, I need to know more details e.g. what kind of work he/she does? what is the problem? When you discussed the problem what was his/her response? was he/she looked serious and sincere in acknowledging the problm? Has he done any effort from his/her side? Did you provide any training?
  

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[Vinay]

It seems you are entering data manually and everytime it is different so hard coding is not possible? What is data entry process – does the operator enter the new information from some hardcopy form? If that is the case, the only best option you have is to get the entered information reverified by another person.
To make a long story short, in one company we cut down entry time from 30 minutes to less than a minute.
 

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[Vinay]

Best wishes but as Erika mentioned in her e-mail, sometimes it is very frustating working in a industry that is very heavily regulated and people are not ready for a change. As a six sigma black belt your job is to deal with conflict management and if you have the best idea present it with good justification, do not get frustated and you would succeed.
 

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[Vinay]

Here is my recommendation:
1. Create a flow chart of the entire process. 2. Set a target for your suppliers 3. Work with your suppliers to understand the bottlenecks, 4. Work on the issue.
I was dealing with a Tier1 electronics manufacturing supplier. We cut down turn around time from 5 work days (1 week) to less than 2 days.  

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[Vinay]

Meeting (conformance to customer’s expectations) and if possible exceeding customer’s expectations.
 

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[Vinay]

We use six sigma projects in our day today life. Whatever is your job function, if you make a significant improvement document all steps that you took to make it happen.
It is not always possible to justify a Return on Investment in terms of dollars.

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[Vinay]

Black Belt Six Sigma includes a cross functional approach as compared to any other certifications. I think others are a subset of BBSS.  

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[Vinay]

Let me know how can I reach you via e-mail or phone call.

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[Vinay]

I would like to see your spreadsheet. I  worked for high volume electronics manufacturing companies and I was also doing business with several large to mid size EMS providerss for over ten years and put together a very tightly controlled process which worked very well for employees, customers and company management.
  

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[Vinay]

I can give you one example. When I was preparing for SSBB certification exam, I was reading about Kano Model (analysis). There are three kinds of customer’s requirements. Dissatisfier, Satisfier and Delighter. I took 2 week guided tour to China six years ago. I put it in the delighter category – more than what I had expected. I have traveled all over the world and took several guided tours but this one was the best. Based on my recommendation, many of my friends took this tour and they had similar experience.
 
I do not know much about Tourism Industry but six sigma principles and tools can be applied on successfully in Tourism Industry.

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[Vinay]

Hi Vinny,
You have very rightly said regarding it…….
Vinny Iam very much passionate about the Sixsigma analysis when today I was surfing the web I saw your mails flying over, I hope that you will be having a brief idea about the projects and analysis, Iam still in the beginers stage so plz feel free to help me if you have any idea about it….to My ID.
 
Regards,
Vinay Kumar 

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[Vinay]

Daniel,
It is the process owner’s prime responsibility to drive FMEA effectively by taking the inputs from team members, however make sure that the team members are being trained/aware on the significance of the RPN number.
The rating is done on a scale of 1 to 10 for all the three parameters as listed by AVY and based on the RPN number we can trigger the mechanism by which our risks can be classified as High, Medium or low.
Generally we seek mitigation and contingency plans to be in place for high risks, either of these plans for medium risks, optional for low risks.
Decide on RPN with team executing the project so as to use FMEA effectively for risk management.

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[Vinay]

Internally or externally, where ever Customers dpeccification is the Gospel for process capability as, customer pays for the product and thus the organization generates revenue.
 
Vinay

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[Vinay]

Dear Ross:
I did note your discussion on Inventory adjustment. The WIP you are thinking of considering as a variable Y, i s one of the pieces of the puzzle, the other main  RED X to look at for correlation is Scrap/defects or poor accountability during receiving ( simple reason that a sophisticated inventory management system hooked up to ERP system is not available).
Hope this provides more answers
Vinay
 
 
 

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[Vinay]

Ravi, Need some more explanation (if it is very simple) with the examples and exact methodology to do it were we do not get into data integrity issues.

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[Vinay]

Sushant / Ronnie,
Let me paraphrase the help required. I have a set of metrics which is defined for the Customer Response Centre and is in line with your suggestions. We track and want to continue to track as Sigma scores instead of the percentages which most in the industry like to follow.
We are acheiving 95-96% each month against standards set by customers but if this data is converted to Sigma value it is lower than 4.0 sigma. The organisation has set 4.0 sigma as the min. acceptable level for all processes including this process. I want guidance to convert the 95% expectations level as base for the sigma calculations any deviation beyond 95% should only be taken as defects. If the 95% targets are met it should equal to 6 sigma. Any defect beyond 95% should be taken as a defect.
Hope the above clarifies more.
Is there a way by which the 95%

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[Vinay]

Sam,
There is no denial that the averages are not the way for any process metrics measurement. However the reality is that in most cases there are two elements to any managment reporting one is to showcase the performance of the team internally / externally and another which we as six sigma teams are more intersted in is to reduce defects.
In this particular case the second objective is addressed to the best of the abilities considering the infrastructure cosntraints however the first objective still needs addressal and some brainstorming as we cannot change much at the current levels without huge tech. investments.

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[Vinay]

Sam,
Thanks for the response. The Customers in this case is the operations who also agree that acheiving 95% is acceptable service levels as per industry standards. If this level is acceptable can we have a solution. In addition there is no denial that Customer needs should be focussed and for that projects are happening to address defects.

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