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Atul Sharma

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About Atul Sharma

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  • Name
    Atul Sharma
  • Company
    Highway Industries Ltd.
  • Designation
    Assistant General Manager

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  1. NO. first of all what is basically a DMAIC OR DMADV? They are data driven quality strategy used for improvement. My some points 1) Do you really recommend dabbawala to hire a DMAIC strategist. 2) If DMAIC is the master tool then why a big names in the world went down and became bankcrupt including manufacturing giants ( dont wana mention name). 3) the 7 wonders of the world was the combine effort of the skill set used. 4) There are lots of alternate ways to carry a projects, example lean. In my point of view you need a team of skilled people who is passionate/motivated/ ready to learn and apply skills, who work to take a vision of the company forward just like an owner will put an efforts to make his company a big brand. In that case every strategy will be successful. Would like to take on comments Regards
  2. Dear All I am really liking this discussion platform Now I hope I l be able to explain exactly what I feel Defect mean any imperfection, short coming or lack in something. Example 1: I have some workers in factory who are running machines...let me talk only about 1 of them, from the data the last breakdown noticed in his machine was 17 years ago...till date he is taking care of his machine and the product is always under control limits. So in this case i can say zero defect is achieved... Example 2: beverages/breweries imdustries from consumer prospective and not producer perspective. Any beverage company product say Pepsi have always got a same taste. Take any bottle you want... (I would like to take on some comments on this if I am wrong). Maggie MASALA tastemaker for instant Every process demands a stringent inspection points or checksheet. some of the points may be done daily, weekly, monthly or yearly. Now strictly adhere to these checkpoints, rules is challenging but will definetely leads to defect free enviornment. What can u say for the people who do not know six sigma, lean or tqm....but still a six sigma certified company with one error in 16 million deliveries (quoted by times of India Feb 9 2013) Dabbawala mumbai And there are many more examples to give. Would like to take some comments Regards
  3. Type 2 error or consumer risk error is very useful in determining sample size. Power and sample size are important and are widely used in our lives. If the pharmaceutical company wants to prove that the medicine is right they have to determine the sample size. Suppose anyone is down with fever and the doctor tells you that the medicine is 99.9% effective, you may ask doctor as to how many patients were considered in the experiment and at what confidence interval. So both the consumer and producer risk can be reduced by increasing sample size. (Obviously increasing sample size will increase the cost of inspection and this is not easy many times). So it is not always true that reducing consumers risk will increase producers risk.
  4. Dear Sumantha That's out of the box... I think you have been lucky in term of money... That can be in case of malfunction of machine....the possibility of defect can cause by following factors MAN MACHINE MATERIAL METHOD ENVIORNMENT MATERIAL HANDLING I call it as 5M and 1E. The above are the reason for variations and thus causing defect.. Maintaining the above in control limits...you will not get the defects...though oppurtunities of variation will always be there... It is also true that achieving zero defect can be very costly since it require lot of inspection to make the product defect free...it also can effect the philosophy of continuous improvement.... Regards
  5. It totally depends how u take zero defect.... Example ATM machine ....please let me know if anyone entered an amount and have got different amount from atm machine... Zero defect is achievable...but it also depend on process which is under observation....
  6. The process maturity model shows you how close your project is to being complete and whether it is capable of improvement, in order to be mature. A mature project has to be completely useful, reliable and continuously improving. The maturity of a process can go from Level 1 (the least mature) to level 5 (the most mature): Level 0 ­ no guarantee of either achieving the desired result or respecting timelines. Level 1 ­ it may be doubtful that the activity is being performed according to the document. Level 2 ­ the activity is being deployed, but there is inconsistency in the deployment. Level 3 ­ no inconsistency between the documented process and the deployed process Level 4 ­ The process is measured against its goals and automated Level 5 ­ The goals that were set for the process are being analysed for achievements and improved regularly. Improving your project's Maturity with the help of a Process Maturity Model For improving your business processes, the Six Sigma DMAIC (Define, Measure, Analyse, Improve, Control) steps can be used: Define: Apply the maturity levels to the organisation, by using a questionnaire to assess the maturity level of each business process. Below is a template for the questionnaire. Measure: use the questionnaire to arrive at each process’ maturity level. Analyse: a plan of action must be created on how to improve the maturity level of specific processes, this way improving the overall level. Improve: redefining or redesigning processes, automation, etc. Control: a control plan must be generated and assessments of maturity levels of processes must be performed
  7. In order to improve profitability, efficiency and effectiveness, there is a continuous focus on eliminating all aspects of the manufacturing process or activity that add no value from your customers perpective Starting with the PPAP to the lot approval and then manufacturing, everything we are doing to convert Raw material to finish goods dispatched to the customer or from approval of customer to be served in service industry, we have a conversion cost to it. Therefore the focus is to make product which is conformance to the requirement of customer. Any activity which is not adding any value and can be eliminated should be done or any activity which is not adding value but cannot be eliminated at the same time should be minimised example (material handling, loading unloading...etc.) to remain in competition... There can be any way by which we can find out and eliminate the waste even simple 5S activity is useful, other way like Value stream mapping, jidoka, automation, kaizen, simplifying process layout, training and awareness, motivation, breaking mind set of employees (which in my case was challenging though regarding productivity) by setting the targets as per capacity and monitoring the same through SLIM, balance scorecard, through suggestion box, benchmarking, work rotation TPM, OEE and there can be many combinations or by making Cross functional teams, projects THANKS and regards Atul sharma
  8. Every data which is measured will show some variation as no two pieces are alike. The variation may be defined as the numerical value used to indicate how widely a piece for wich the data has been taken varies. We always have a noice factor in a process which cause variation and therefore we get the bell shape curve instead of one vertical line of target (means every dimension is equal to the target without variation). Thus it is always important to understand what kind of variation is affecting the process as the course of action to be taken depends on the type of variance. Common cause of variance: it is also referred to as variation due to natural cause, noise, and random cause. Now these causes are an inherent part of a process. This kind of variance will eventually happen and there is nothing we can do about them. Any specific actions taken cannot prevent this failure from occurring. It is ongoing, consistent and predictable. Taking a day to day example for keeping spare parts for my car at my home... I know my car needs a tire pressure pump or cleaning kit and vacuum cleaner for cleaning purpose and therefore I will store these products for maintaining my car. I would not store a spare set of tires in case the set of tires get stolen from my car. Therefore the common cause of variation is predictable in nature although sometimes it is difficult to predict its not always obvious. This variation will do more harm to the process over the period of time. They lie within 3 standard deviations from the mean where 99.73% of values are expected to be found. When shown in control charts these are a few random points shown within the control limit. These variations require a management action to rectify. If your control chart shows only common cause of variation the process is said to be stable. Let us take another example as a person living in metropolitan cities one always know how much early one should start their travel to reach office in the morning by keeping the margin so they don't get late. Special cause of variance In the above example if suddenly a major accident takes place on the road which halts the traffic, then your travel time will become more and you will reach late to office. So these causes refer to the unexpected variation that effects a process. These are also known as the assignable cause. These are the causes which are unusual or non-quantifiable variation. On control charts these variation lies beyond the preferred control limit. On these variations are identified they are to be addressed immediately so as to prevent recurrence of it in the project. These are not usually part of normal process. The special cause cannot be taken or treated as a normal cause in a project as it includes cost and since the nature of assignable.cause is unpredictable we will not be able to predict the same.
  9. SIPOC or COPIS provides a simple framework while performing any process discovery or any improvemment activity. Once need to know the broad picture and how it can fit into the business. SIPOC is a high-level view of the “as is” state of a process under investigation It is very important to get a high level understanding of the scope in the process first, so one should use sipoc when any improvement activity is underway. SIPOC helps provides a structured way to discuss a process and get consensus and understanding on what it involves before we rushoff to draw process maps. It’s really useful when any of these points aren’t clear: Who supplies inputs to the process? What specifications are placed on the inputs? Who are the true customers of the process? What are the requirements of the customers? Therefore sipoc is basically define a process before you map, measure or improve them. It defines the boundary or scope of your improvement area It gibes the visual presentation of the problem. It is a structure way to discuss the process.
  10. In an automated machine a small abnormality can produce hundreds of defective products quickly. Hence mass production of defective products cannot be prevented in the automated machine In order to eliminate this shortcoming of the automated machine, Toyota uses Autonomation, i.e. Automation with a human touch. This idea originated from Toyoda Sakichi with the invention of auto-activated weaving machine. This weaving machine will stop instantly if any one of the threads broke. The machine automated with a human touch is equipped with automatic stopping devices for abnormal situations, safety devices, fixed position stopping devices and Poka Yoke fool proofing system for prevention defective products. Autonomation changes the role of an operator in a shop floor. The Operator is not needed when the machine is working normally and only when the machine stops because of an abnormal situation it gets human attention. So one worker can attend several machines. Thus we can increase production efficiency using Autonomation. Also stopping machine when there is an abnormality forces awareness on everyone. For example in manufacturing PET bottles through injection molding. The temperature variation can cause a huge amount of defects/ rejections until and unless detected by quality personal. Whereas in the case of autonomation we can link the dimesion of bottle through auto gauging station linked with machine. The Autocorrection mode will start if there is any deviation in dimensions detected and the rejection of rest of the bottles can be avoided. Jidoka/Autonomation 1. If a malfunction occurs, the machine shall detect the malfunction and stop itself. 2. No defective parts will be produced. Breakdowns of machines, molds and/or jigs can be prevented. 3. Easy to locate the cause of any malfunction and implement measures to prevent recurrence. Automation 1. If a malfunction occurs, the machine will continue operating until someone turns off a switch. 2. If defects occur, detection of these defects will be delayed, possible breakdown of machines, molds, and/or jigs may result. 3. Difficult to locate the cause of malfunctions at an early stage and difficult to implement measures to prevent recurrence.
  11. In hypothesis testing, the statistician is likely to prove that whether the data is statistically significant and unlikely to have occurred by chance alone. A hypothesis test is a test of significance. Once the statistician has collected data and you test hypothesis against the likelihood of chance, he draws his final conclusion. If he reject the null hypothesis than he is claiming that the result is statistically significant and that it did not happen by luck or chance. As such, the outcome proves the alternative hypothesis. If he fails to reject the null hypothesis than it is concluded that you did not find an effect or difference in your study. Hypothesis testing is used in the six sigma Analyse phase for screening potential causes.
  12. I put forward the first point...the human error is not possible at all As in our forging industry we have implemented poka yoke for underheat and overheat billets as per die specification...as the induction billet heater will over heat or under heat billet...it can prove to be very fatal for the person working on forging as well as die...the temp of billets is also important in view of rejection since the pressure and the impact of vertical die on component is also a deciding factor for the life of die as well as providing first pass yield. So the forher will always get a right temp billet to work on in its desired time.. Have a nice day Regards
  13. Takt time is actually a german word for beat (as in drum beat) adopted by japanese and in term by lean community. It is very useful as the relation between cycle time and customer demand rate matters, because it helps us to understand the waste and oppurtunity. It helps us to understand what we are heading towards. It aligns process towards needs. Formula for takt time is = Available minutes for production / required units of production For me i think "Takt is a choice" by this i mean that it is more than maths of customer demand rate over time, actually it is an organisation choice of what to establish as demand. In todays dynamic world demand constantly change so do we use the last actual demand or forcast demand or seasonality demand and over what time period. It seems to me that if we are able to establish relation between the time period at which changes in operations can be made in order to respond changing takt. It need a strategic decesions for doing the right things over a period of time. Have a nice day! Atul Sharma
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