Srivasu Kompala

Single piece flow really useful for the industries like just in time production. First industry which comes in my mind is restaurants. Some times they cook huge quantity and kept ready to serve, now orders system implemented where orders will be taken first and produce the food and serve to customers. In banking before single flow huge choas in counters at branches because of dedicated counters, after introducing token system, customer service become smoother and variety of customers can be handled by any counter. In IT offices, people print huge quantity of papers some, and will not collect many times will not collect it. These days Access card system implemented in printers, post swiping only printer will print the pages. And serve only who needs the print and saves huge cost to company

My immediate question to the management is to understand the current pain areas. Will buy some time to do first level study to understand the various business that the organisation involves. Post study make a pack and discuss about vision and mission statement , Scope to improve road blocks to achieve the vision and mission statement. discuss about 7 waste tool with example how it can benefit customer/organisation/culture of employees. and discuss their buy in, communication plans, risk & mitigation plans and implantation plans in the Implementation Plan the following activities discussed with time lines Schedule call with all PMs Discuss about vision and mission Pain areas Discuss about the tool and benefits identify the SPOC Train the SPOC identify the critical process conduct process review (VA/NVA) post review most of the process within all depts., prioritise the Conduct a session with management take their opinion before implementing the tool.

Descriptive analytics: perform statistical analysis on the data observed from a particular group only. The outcome of analysis/result/conclusions made for the specific group data, No conclusions beyond the group and any similarity to those outside the group cannot be assumed. Predictive analytics: Perform statistical analysis from past/present data of organisation and predict trends/behaviours. Using this analytics we can perform any type of unknown events, it could be in the past, present or for future Prescriptive Analytics: The analytics enables multiple solution/possible actions. The analytics quantifies the effect of future decisions in order to advice on possible outcomes before the decisions area actually made. Prescriptive analytics predicts not only what will happen, but also why it will happen providing recommendations regarding actions that will take advantage of the predictions. In Lean Six sigma, All statistics performed on structured data. But on Business Analytics(Descriptive, Predictive, prescriptive) any kind of data can be used and the raw data need to be organised into structured data. Descriptive Analytics i believe Six sigma uses extensively, predictive analytics little bit functionality used in Six Sigma. But in predictive analytics future event or issues can be predicted, this prediction six sigma not contributing.

Process Stability Capability to measure the resultant of the process is repeatable and consistent measure process ability whether it meet specifications Process distribution is consitent over the time indicates how good inputs are Capability cannot be performed if process is not stable A Stable process is one that is operating within specified control limits and without excessive variation A Capable Process is a process that has achieved it's specified quality and product goals and objectives

Correlation Cause and Effect Definition To test the level of relationship of two or more variables study the effective way of identifying causality between variables. detailed if the value of one variable increases or decreases, the other variable also increases or decreases the action or occurrence of one variable can cause or change the other variable. Benefits can predict future events can be controlled the impact to occur due to causes Example smoking is correlated with alcoholism smoking causes an increase in the risk of developing lung cancer

In the competitive world sustaining with business is one of tough task. to sustain the all products needs to review periodically with respect to customer expectation. To understandd customer expectation /requirements we need to go to market research. VOC is one of the technique help to understand customer needs. Post completing the VOC, categorise and prioritise the requirements and implement the changes in the products and release the products Studies shown that the maintain the positive customer experience can help tangible return on investment. These VOC helps to improve the process, effective employee engagement, cost reductions etc. The VOC can be captured in various forms like internet search database, feedback form, customer complaints , historical complaints. VOC also can go wrong if we are not identified right people to capture feedback. Customer requirement always changing time to time. sometimes customer may not give right feedback and its very difficult to judge whether the feedback is genuine.

Correction Whenever a problem occurs, need to look into various aspects several aspects 1) identify the magnitude of the problem. 2) identify how to prevent it from getting bigger. 3) How to address current situation. We can also termed as control the Damage. Although correction steps to correct the problem it has no bearing on cause. Corrective action A process resulted non conformances output on customer specifications. The actions taken against non conformances is corrective action. Corrective actions are reactive actions A corrective action plan is a strategy for correcting or eliminating a problem that has already occurred or been identified . Preventive action Identify the possible non conformances during the process execution can be termed as preventive action. These action signals whenever process is about result non conformances. Preventive actions are proactive actions. Example scenario : A customer orders 500 parts, but only 450 are delivered. Correction – Fix the current issue. Get the customer 50 more parts Corrective Action – Why were we short?. Operator miscounted 9 boxes of 50 as 10 boxes of 50 Preventive Action – make sure it doesn’t happen again. Weigh products on scale so you know if quantity is met.

A Check Sheet is a tool used to systematically collect data on the frequency of an occurrence of defects, patterns and possible causes, ad defected measured by quantitative or qualitative. Checksheet cannot be eliminated in education of QC. because it is one to the tool to measure quality of the process to improve the process efficiency and effectiveness. so defects needs to be identified. But these checksheet are losing the original formats from paper sheets to softcopy due to various softwares introduced.

Push flow (make-to-stock) production/manufacturing based on market forecast and it is not based on actual demand. There is no control/limit on WIP A push flow involves taking the product directly to the customer. Push System Examples Trade show promotions: encourages retailer demand Showrooms : Selling directly to customers Wholesale retailer: Negotiation with retailers to stock the product Supply chain: allowing retailers an efficient supply FMCG : lower value items selling Pull flow (make-to-order) production/manufacturing based on actual customer demand or based on Just in time. in Other ways Limit the WIP. In Pull flow, if downstream signals to upstream on demand, then upstream signals to produce/manufacture the materials. Customer actively looking the products and orders. this strategy requires highly visible brand. by branding customer demand can be increased. Pull Flow Examples Advertising and mass media promotion : By promotional campaigns gain customer demand Word of mouth referrals : influence customer for referrals and create demand Customer relationship management Sales promotions and discounts Why pull system is not practical in some situations Cultivation is an example for this scenario. A farmer cultivates paddy, he is not worried about demand, he crops and sold to agents. Here only push system is possible pull cannot be implemented. main reason a crop take minimum 3 months to cultivate. In a bakery, puffs cooked first and sold approximate quantity based on periodical sales. This is also a push system From above 2 examples, wherever customer demand cannot be predicted or have higher variations, in those industries pull system cannot be implemented.

Every business serves a purpose of customers via processes. These processes gives output as per customers needs. To execute a process cost is incurred where customer willing to pay. Quality of cost need to measured to conclude profits made by business There are 2 types of cost quality 1) Cost Of Good Quality (COGQ), 2) Cost of Poor Quality (COPQ). Every process has variations whether the variation is within control limits(customer acceptance limits). Process output is within limits, can be called as COGQ, process output is beyond limits can be termed as COPQ. Cost of Quality(COQ) = COGQ + COPQ let assume 1000 items produced by process. and delivered to customer, but customer accepted 900 items which is COGQ and rejected 100 items which is COPQ. COGQ is not required to discuss much, customer willing to pay. COPQ need to be analysed to improve business profits and reduce operations cost. How to calculate COPQ Few organisation calculates quality cost traditional methods like scrap, rework, and returned materials. These cost are directly emerging from production. There are external factor also influence failure cost such exeternal services by companies the use of the supply-chain etc. it's important to identify bot internal and external cost CoPQ = IFC + EXC, where: IFC = Scrap Costs + Rework Costs EFC = Returned Product Costs + Warranty Costs + Product Recall Costs Costs incurred internally and externally are caused not only by defects in products, but also by inefficiencies in production and processes. A more in-depth list of factors affecting IFC and EFC is below. Factors Affecting Internal Failure Costs Weaknesses in quality resolution (CAPA/FMEA) Delayed work schedules Poor Materials Planning Materials shortages Equipment downtime Materials review Reengineering/redesigning products Factors Affecting External Failure Costs Poor service management Unresolved customer complaints Weak enterprise communication Environmental/sustainability nonconformances Adverse reputation events Improving the Cost of Poor Quality Small improvements in IFC and EFC can bring into aggregate CoPQ improvements very quickly.

In Business excellence/Process excellence/Six sigma projects, One of the common pain in any business is process variation. During continuous improvement project reducing process variation is one of the major goal is reduce variation. To reduce process first causes need to identified. there are 2 types of causes 1) common causes, 2) special causes. Common Causes This cause frequently occurs in a process, which can be predictable by historical data Example While we are driving to office by a road, we come know the road conditions, traffic jams, signal timings, due to one of the reason there is delay to office to reach. here road condition, traffic jam, signals are common causes. Special Causes This cause is uncertain in a process which cannot be predictable and not controllable have to live with it. Example. In the above example drive to office, traffic jam due to CM/PM travelling on same road which will not happen daily. this situation we cannot controllable Misjudging if we misjudge common cause as Special cause, we may fail implement controls which can be controllable if we misjudge special cause as common cause, we will undergo improvement project which is not controllable. So categorising the causes in appropriate is more critical to improvement project.

SIPOC Stands for Supplier Input Process Output Customer. The tool is widely used in Six sigma and BPM projects. The tool is used at early stage of process improvement and used to understand the high level process followed in as is State at define phase. It is critical to understand the relationships that exist within the process, customers and suppliers. without understanding these facts we cannot able to improve the process. Suppliers and Customer can be internal or external to organisation who can influence the functionality of the process. Inputs and outputs are materials, services or information process list of actions performed outputs as per customer requirements with helps of inputs. The uses of the SIPOC - Gives high-level overview of the process - Helps to define new process - Helps to understand the boundaries of a process

FTA is top down failure analysis tool when system or process is in undesired state, the system or process is analysed using Boolean logic. This tool used mainly where high safety measure have to be implemented like aerospace, nuclear power, chemical and process, pharma, pertro and etc. Why mainly the FTA used in Safety Hazard industry? Failing to implement all safety measures can damage environment, loss of human life, can damage economy and reputation loss of county. It is very critical to find all failures and failures causes and classify sever ones. and perform micros level analysis for all severe ones because. FTA can be used in any process as a proactive/reactive condition even in safety hazard industries. finding failures is one of the critical activity for any process and to achieve first time right. one can perform FTA at the time of process design, or one can perform when process is failed performing FTA increases success rate of the process / system

Personal Excellence - An Individual how well handling activities, issues, problems and changes Process excellence - any process which results solutions to customer, within timeline, with reduced variations and with high quality Operational Excellence - for any process how well leadership/management team organised to meet customer expectation and implements tools, process and policies and people and ensure to execute business within budget Business Excellence : How business goals defined and communicated to down level and how well changes handled. All 4 components are key to any business, all have very strong bind within each other.