Vishwadeep Khatri from Benchmark Six Sigma recently interviewed Rakesh Sethi, who is an Assistant Manager, Quality at Abhishek Industries (Flagship company of Trident Group) to find out how Six Sigma training has been shaping his career.
BSS : Rakesh, can you share with us some details of your career journey?
Rakesh Sethi: I started my career with some research projects as I have completed my PhD in Chemical Engineering. I have spent my last one and a half years in continual improvement projects at Abhishek Industries. Abhishek Industries is a leading textile company currently Number 2 in India and Number 5 in the world.
BSS: You have undergone Black Belt training from Benchmark. How was your experience?
Rakesh Sethi: It was a very good learning experience. On Six Sigma front, we have been working on three focus areas which are
1. Yield improvement - The yield which was 89-90% initially is now up 97.26%. Increase in yield by 1% saves close to 55 lacs for the company.
2. New product development - We have focussed on eliminating production problems early (during sampling itself). The feasibility studies are now done in advance. Capacity and technical requirements for an order are understood in advance. This has eliminated air shipments which had a cost of Rs. 7-8 Crores every year.
3. System and physical balancing - The data in the SAP system needs to match with physical data.
BSS: What kind of benefits have you derived due to Six Sigma knowledge?
Rakesh Sethi: A systematic analysis mechanism like Six Sigma is a must. System development is good for employees as well as companies. DMAIC makes it easy to communicate with senior management and provides a structured approach.
BSS: Why do you think the methodology is not being used much in textile industry?
Rakesh Sethi: Three reasons
1. Automation opportunities are limited.
2. Manual error cannot be eliminated altogether.
3. Management thought process - Abhishek Industries management has progressive thinking and supports initiatives of this kind. This is not the case he bare minimum requirement for a project manager is Green Belt training. With clients asking for higher value, project managers should ideally be Black Belt trained.
BSS: What are the steps the company is taking on continual improvement front?
Rakesh Sethi: We are involving 13000 employees in 7 QC, Why-why analysis. Everybody maintains record of efforts in 5S, 4M, 3M, 6S, 7S and multiskilling.
We have initiatives like "muskaan" and "shaan" for continual improvement and 5S. Everyone knows the meaning of these terms and takes pride in being involved.
BSS: Do you have any improvement suggestion for Benchmark Six Sigma?
Rakesh Sethi: In our company, anyone who undergoes a training program needs to make a presentation about the learning and applications. My immediate presentation went well and I have continued my efforts in this field and have learnt lot more with books and additional sources of knowledge.
It would be great if Benchmark can make such a presentation a requirement and verify that presentation has been made appropriately.
BSS: Thank you for your feedback and time & willingness to share your experience with the Six Sigma community.