Services – 3GenConsultants
3 GEN CONSULTANTS - T & D SUCCESS STORY
Why do we train our industrial work associates?
We train work associates (employees) to improve their skills, knowledge and attitude, leading to increased productivity, better performance, higher employee satisfaction, and ultimately, a more successful business by enhancing their ability to perform their jobs effectively, reducing errors, and fostering a sense of value and engagement within the company.
Results we see after training the work associates (employees):
1) Improved performance:
Our training equipped various industries employees with the necessary skills, knowledge and better attitude to perform their tasks more efficiently and confidently, leading to better results.
2) Increased productivity:
Our well-trained employees make fewer mistakes and complete tasks faster day by day, resulting in higher productivity continuously.
3) Employee retention:
Investing in employee development through our training makes employees feel valued and appreciated, which can lead to lower turnover rates in the industry.
4) Employee engagement:
Our training activities demonstrates a company's commitment to employee growth, boosting morale and engagement. Employees are totally committed to helping their organisation achieve its goals.
5) Adaptability to change:
Our training helps employees stay updated with industry trends and new technologies, allowing them to adapt various new methods / tools.
6) Career development:
Our training programs are preparing employees for promotions and new higher responsibilities within the organization.
7) Customer satisfaction:
Our well-trained employees are providing better customer service, leading to higher customer satisfaction.
8) Reduced supervision needs:
Our training programs help employees to work more independently with confidence, requiring less supervision.
9) Addressing performance gaps:
Our training programs are designed to address specific areas where an employee needs improvement, as identified in monthly performance reviews in the industry.
10) Reduced wastage:
We train the people to make good, safe and economical use of the company's materials, tools and equipment. Accidents and equipment damage will be minimized, and this will keep the workplace with less and boost the continuous waste reduction activities.
The following 30 Lean Tools are implemented in various industries to meet the company’s business objectives:
1. Kaizen
2. Jidoka
3. Poka-yoke
4. Visual Management
5. Kanban
6. Heijunka
7. Just in Time
8. Takt time (To meet customer demand)
9. Bottleneck analysis
10. 3 GEN (Genba walk) approach
11. Hoshin Kanri (TQM)
12. Overall Equipment Effectiveness (OEE)
13. Standardized work (TQM)
14. Autonomous Maintenance (TPM)
15. Planned Maintenance (TPM)
16. Quality Maintenance (TPM)
17. Lean Daily Work Management (TQM)
18. Total Employee Involvement – QC (TQM)
19. Cross Functional Team (TQM)
20. Root cause analysis
21. Value stream Mapping (VSM)
22. Continuous flow
23. 7 Wastes elimination
24. Six big losses reduction
25. KRA & KPI achievement
26. 5S Practices (TQE)
27. SMED (Quick Change Over)
28. PDCA & SDCA (Problem solving & sustenance)
29. POUS (Point Of Use Storage)
30. SHE (Safety, Health & Environment)
In addition to the 30 Lean Tools training programs, based on the industries request, we are visiting the industries periodically (mostly monthly) to see the status of the training input implementation process and providing additional inputs or guidance to improve the implementation of the above (30 tools) Best Practices.
To motivate the work force to do better and better continuously, we are conducting the monthly AUDIT on various Japanese Management Practices and give audit score for the above 30 tools or practices. The best performers (or best Team) will be awarded during the monthly Total Employee Involvement (TEI) day.
Look forward to implement the above 30 tools for improving P,Q,C,D,S & M (Productivity, Quality, Cost reduction, Delivery on time, Safety & Morale boosting) in your factory / organization.
LEAN SIX SIGMA TRAINING PROGRAM
Background:
Lean Six Sigma seeks to improve employee and company performance by eliminating the waste of resources and process / product defects. It combines the process improvement methods of Six Sigma and lean enterprise. Lean Six Sigma helps to establish a clear path to achieving improvement objectives.
While created initially for the manufacturing floor, Lean Six Sigma can benefit every department with a focus on measuring performance indicators (KPI), not just outcomes. This can apply to financial operations, customer service and human resources as much as it does manufacturing processes.
Six Sigma in manufacturing optimizes processes by minimizing variation and defects through a systematic approach.
It was introduced by an American engineer Mr. Bill Smith while working at Motorola in 1986.
Why is Lean Six Sigma so popular?
Predictable cycle time, predictable quality output and predictable costs can lead to better customer service, fewer complaints, and higher profits. This predictability becomes a tremendous advantage for an organization when operating in an environment of fast-moving changes.
Which Indian company uses Six Sigma?
Some of the well-known Six Sigma Indian companies include
Tata Motors, Wipro Technologies, Infosys, Reliance Industries, and Mahindra.
Lean Six Sigma which allows enterprises to use data to eliminate defects and variations in processes has become one of the most powerful frameworks to deliver better products and services and be efficient at the same time.
Lean Six Sigma is a combination of two different management methodologies:
Lean Manufacturing and Six Sigma.
In 2006, Motorola reported saving $17 billion using Six Sigma.
Objectives:
After the completion of the program, the participants will be able to:
1) Identify and reduce the waste – DOWNTIME- in their daily work.
2) Reduce the WIP inventory in the Genba.
3) Improve the process flow without waiting or stoppage using VSM.
4) Reduction of non- value added activities in the daily work.
5) Reduce the inventory holding cost and increase inventory turnover ratio using JIT.
6) Understand the process, identify the areas of inefficiency, and suggest ways to streamline the process and increase productivity using time and motion study.
7) Reduction of variation in the process / output from their actual values using DMAIC tools.
Program Contents:
1) Introduction to Lean and Six Sigma methodologies.
2) Waste – DOWNTIME- elimination process
3) Kanban practice
4) Value Stream Mapping – VSM preparation
5) Define, Measure, Analyze, Improve and Control (DMAIC)
6) Case studies
Evaluation methodologies:
Intermediate exercise / test will be conducted at the end of each session.
Totally eight sessions for two days.
At the end of the eighth session, the final test will be conducted to understand the participants learning level.
Training methodologies:
1) Lecture using colourful PPT slides. Medium of instruction Tamil or English to suit the participants.
2) Visuals / videos are used for better understanding.
3) Exercises are used to reinforce the learning level.
Implementation:
Very happy to implement the LSS (Lean Six Sigma) practices followed by the training input. Doing periodical assessment and guiding the people to improve the LSS practices continuously.
Meant for whom:
Managers, Engineers, Supervisors, work associate leaders and work associates working in all the departments.
Faculty & Traits:
The faculty has experience in the range of 30 to 35 years in imparting best Japanese management practices.
Certified JMP implementer from AOTS, Japan.
Program Duration:
Program duration: Two days
Number of faculties: One
LEAN SIX SIGMA (LSS)
PRACTICES
SALIENT FEATURES
I) What is Lean Six Sigma (LSS)?
Lean Six Sigma is a team-focused managerial approach that seeks to improve performance by eliminating resource waste and defects. It combines Six Sigma methods and tools with the Lean manufacturing / Lean enterprise philosophy. It strives to eliminate the waste of physical resources, time, effort, and talent while assuring quality in production and organizational processes.
Lean Six Sigma teaches that any use of resources that doesn’t create VALUE for the end customer is considered a waste and should be eliminated.
Lean Six Sigma helps to establish a clear path to achieving improvement objectives.
The Lean strategy was established by Toyota in the 1940s and attempts to streamline operational processes, from manufacturing to transactions.
Six Sigma originated in the 1980s and seeks to improve output quality by reducing defects.
II) Why Lean Six Sigma (LSS) is required in your organization?
1) To eliminate the EIGHT wastes in the daily work - DOWNTIME-.
2) Reduction of WIP between operations using Kanban.
3) Reduction of stoppage / waiting and improving the process flow using VSM.
4) Reduction of non-value added activities using JIT
5) Reduction of variation in the process / output.
Lean Six Sigma is a business process improvement methodology formulated to eliminate problems, remove waste and inefficiency, improve employee working conditions, and better serve customer needs.
III) Benefits of Lean Six Sigma (LSS) in your organization:
Lean Six Sigma training can benefit individuals by expanding their skills and knowledge in continuous process improvement. It can also benefit organizations in many ways, including the following.
1. Eliminating Errors
The goal of Six Sigma is to reduce the number of defects or errors in any process to 3.4 per one million outcomes. That’s an extremely ambitious goal, but one that is achievable by putting Six Sigma methodologies into practice, starting with the popular DMAIC approach.
2. Cutting Waste
Lean focuses on eliminating the waste in an operation with an eye of cutting costs and creating products that best meet customer expectations.
3. Saving Costs
By eliminating errors and waste, organizations make their processes more efficient, saving money. Lean Six Sigma improves not only processes, but also can lead to better management of inventory, supply chains and product development.
4. A New Company Culture
Lean Six Sigma is only effective if a company adopts a culture of continuous process improvement. While certain projects end successfully, the overall work of improvement never ends.
5. It Reaches All Departments
While created initially for the manufacturing floor, Lean Six Sigma can benefit every department with a focus on measuring performance indicators, not just outcomes. This can apply to financial operations, customer service and human resources as much as it does manufacturing processes.
6. Higher Customer (Internal & External) Satisfaction and Loyalty
By focusing on the needs of customers and eliminating everything that doesn’t meet those needs, businesses generate a higher level of satisfaction and loyalty among their customers.
7. Higher Employee Satisfaction
If included in the Lean Six Sigma effort, employees will feel more engaged in their jobs, loyalty to a company and better bonded with co-workers.
8. Attracting Business Partners
Applied properly, Lean Six Sigma will lead to more business success. That, in turn, will attract better business partners who want to partner with a successful organization.
9. Better Risk Management and Strategic Planning
By putting the proper Lean Six Sigma tools to work, organizations can better identify potential risks to their business and take steps to mitigate those risks.
10. Establishing ‘3E’ work culture
Everyone will follow the ‘3E’ in their daily work.
a) Effectiveness – Doing the right things every day,
b) Doing the things rightly without deviation or mistake and
c) Enjoyment – Enjoying their everyday work after seeing the success.
IV) Evaluation of participants understanding level during the Training program:
1) Totally eight sessions for two days.
2) Each session is having test to evaluate the understanding level.
3) At the end of the session, the test papers are evaluated by the faculty and the feedback is given to the participants. If require, additional training input is given as corrective actions during the next session by the faculty.
V) Post Training program Review:
1) The faculty / consultant will review the participant’s improvement activities in each project and then provide feedback for further improvement. Each project should have target, results achieved and the gap between target and result.
2) Based on the participant’s ex-ordinary performance, the participant will be upgraded to next higher level belt.
(Basic starts at YELLOW colour Belt, then GREEN colour, BLACK colour and MASTER BLACK colour belt).
3) All the improvement projects are aimed to reach the factory KPI (Key Performance indicators).
VI) LSS Master Board:
1) In the LSS Master board, each participant name with photo is displayed along with Belt colour and number of projects successfully completed.
2) Every month after the project progress review, the board will be updated by the LSS – Champion.
3) Unlike other best practices, this LSS practice visual display motivate each person to show their creativity in thinking and hidden talents to reach the factory KPI.