India

Six sigma 

KPMG in India offers six sigma based services that incorporate metrics and statistical concepts for problem solving across various domains and industries.

 

KPMG’s six sigma programme provides an opportunity to build early competence that can help individuals take vital organisational decisions using analytical skills.


The following services are provided by KPMG:

 

1. Organisation wide corporate deployment

1.1 Six Sigma Facilitation Based Project Advisory

 

 The methodology consists of following steps: 
 

  • Understand the organisation culture and requirements
  • Provide Green Belt and Black Belt training
  • Facilitate project selections
  • Assess the project progress
  • Mentor wherever required
  • Transition
  • Signoff

 

 

1.2 Six sigma Full Scale Implementation Advisory

 

  • Understanding the organisation culture and requirements
  • Identifying of chronic problem areas using dip stick study
  • Selecting projects across different areas
  • Setting the mutually agreed SMART goals for the projects
  • Understanding the complete process in AS-IS state
  • Targeting the improvements using six sigma approach and data analysis
  • Improvement suggestion generation and selection via brainstorming with key stakeholders
  • Solution implementation and monitoring
  • Tracking the project progress
  • Project result analysis
  • Defining the to-be process
  • Top management and stakeholders’ presentation
  • Signoff

 

These steps may be customised to better suit the requirements of the audience and maturity level of the organisation.

2. Six sigma based – Public Programmes (for individual participation)

2.1 Six sigma Green Belt Programme 

 

Topics Covered:

 

  • Project charter, VOC to CTQs, Kano model, SIPOC
  • Types of data, sampling strategy
  • Fishbone diagram, data collection plan
  • Measurement system analysis
  • Graphical analysis, Run chart, segmentation & stratification
  • Box plot, rolled throughput yield, Pareto
  • Process capability, normality study
  • Concept of lean, process map analysis
  • Hypothesis testing, correlation and regression
  • Idea generation, TRIZ, brainstorming
  • C&B matrix, mistake proofing, FMEA
  • Process management charts, SPC, response plan
  • Change management tools, project closure 

 

 

2.2 Six Sigma Black Belt Program

 

Topics Covered:

 

  • Basic concepts: Defects, DPMO, DPO, Rolled Throughput Yield (RTY); Principle of first time right; cost of poor quality
  • Enterprise wide Six Sigma rollout: project selection and prioritisation
  • Developing the project charter
  • Capturing Voice of Customer (VOC) and its relevance
  • Kano model: study customer delight factors
  • Process mapping using COPIS/SIPOC model
  • Basic quality tools: CTQ matrix, Quality Function Deployment (QFD), FMEA (Failure Mode and effect Analysis), fish bone diagram and Pareto chart
  • Failure Mode Effects Analysis (FMEA)
  • Performance standards: defect, unit and opportunity
  • CTQ characteristics: characteristic, unit of measure, target, specification limit, desired level of quality
  • Data collection plan: five step data collection plan
  • Measure Measurement Systems Analysis (MSA) using variable data: gage R&R
  • Measurement system characteristics: tolerance; precision; accuracy; linearity, stability
  • MSA for destructive tests, nested study and crossed gage R&R study
  • Attribute agreement analysis with different type of data like; nominal, binomial and ordinal
  • Change management tools like A-RM-I, GRPI, stakeholder analysis, elevator speech, threat and opportunity
  • Application of change management tools in Six Sigma projects
  • Team exercise on change management tools
  • Data types: discrete and continuous
  • Sampling plan and sampling technique
  • Basic quality tools: CTQ matrix, Quality Function Deployment (QFD), FMEA (Failure Mode and effect Analysis), fish bone diagram and Pareto chart
  • Process capability analysis: specification limits (double sided; single sided)
  • Extensive study on process capability indices like: Cp, Cpk, Cpm, Zst, Zlt, Zshift, ppm (DPMO)
  • Baseline Sigma capability: Zst and Zlt
  • Z calculator tool and use of Z conversion table
  • Normality
  • Individual distribution identification
  • Box Cox transformation
  • Normality test - Anderson Darling normality test
  • Z calculation
  • Z calculation with attribute and continuous data
  • Subjective analysis tools: cause and effects matrix; Box Whisker plots, run chart, time series plot, multi variate chart
  • Subgroups and sampling: rational subgroups; other data sub grouping techniques
  • Pareto charts with class exercise using Minitab statistical tool
  • Correlation and regression: linear regression, general linear model
  • Hypothesis: formation, alpha and beta risks; test of means, variances, ratios
  • Hypothesis testing of one Y,X pair: chi square, ANOVA (Analysis of Variance)
  • Analysis of multiple variables: concept of rational sub grouping, ANOVA (Analysis of Variance)
  • Case study on hypothesis testing: concept of statistical test flow chart
  • Concept of operating parameters and critical elements
  • Establish operating tolerances on Xs (When X is continuous in nature)
  • Transfer function Y= mx + C
  • MSA on Xs
  • Determine improved process capability
  • Select SPC charts (attribute data and variable data)
  • Introduce control charts: continuous and discrete data
  • Discrete data control charts (P, U, defects vs. defectives). Variable data control charts (I-MR and X-Bar R)
  • Mistake proofing with Poka Yoke
  • Cost benefit analysis and reporting: linkages to profit and loss
  • Designing an implementation plan
  • Class exercise on using control charts
  • Capturing project learning/project documentation
  • Lessons learned: documenting repeatable and replicable do's and don'ts on your project
  • D-M-A-I-C recap (5 Phase of 6 Sigma)
  • Class exercise to integrate learning’s and presentation by individual teams
  • Black Belt project case study discussion
  • Capturing project learning/project documentation
  • Lessons learned
  • Final questions and answers

For any further queries contact us at:
Email: in-fmsixsigma@kpmg.com

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