Escolar Documentos
Profissional Documentos
Cultura Documentos
Organization Strategy
Guest Lecture at IIT Roorkee
Naresh Chawla
Six Sigma Master Black Belt
Certified Productivity Practitioner (APO, Japan)
Naresh Chawla,
Naresh Chawla,
Naresh Chawla,
Naresh Chawla,
Motorola Story
First Mobile phone weighing 1 kg (1973)
Commercial cell phone- DynaTAC 8000X
790 gm (1983)
Naresh Chawla,
Naresh Chawla,
Naresh Chawla,
Naresh Chawla,
Z= x
=6
6 5 4 3 2 1
1 2 3 4 5 6
Naresh Chawla,
1.5
6 5 4 3 2 1
1 2 3 4 5 6
Naresh Chawla,
Z = (X-) = Constant
Size of door = Tolerance= VoC
Size of the truck = 3s = VoP
As Defects
Go Down . . .
-3s1 +3s1
11
Z
. . . Sigma
Capability
Goes Up
Naresh Chawla,
Achievement - 1987
Won Malcolm
Baldrige National
Quality Award
Five-fold growth in
sales, with profits
climbing 20 percent per
year.
Cumulative savings
pegged at $14 billion
13
14
Naresh Chawla,
15
Naresh Chawla,
16
Naresh Chawla,
Jack Welch
17
nareshchawla@tqmbizschool.org
- Customer Centricity
- Process Orientation
- Data and fact driven
18
Naresh Chawla,
nareshchawla@tqmbizschool.org
Customer
Requirements
Market Share
RoI
EBITA
Superior
Reliability
Process
Capabilities
Robust
Process
Predictable
Results
Consistent
Performance
Customer
Satisfaction
Business
Results
On-Time
Delivery
Material
Capabilities
21
Lower Costs
Naresh Chawla,
Measure
Analyze
Define As is
Situation
(Detailed
Process Map)
Identify
patterns
through data
anlysis
Identify
Potential
Causes (xs)
Validate
Measurement
Systems
Quantify
Current
Process
Performance
Prioritize
possible
root causes
Validate
possible root
causes
Control
Improve
Generate
Potential
solutions
Select Best
Solution
Test Solution
(Piloting)
Prepare
and
Implement
Control
Plan
Implement
Full Scale
Solution
Statistical
Statistical
Evidence of
Evidence
improvements
that
improveme
nts are
sustainable
Validate
Financial
Gains
Naresh Chawla,
Normality of Data
2 DPMO
Hypothesis testing
10 Correlation and
Regression
4 Measurement System
Analysis
5 Process capability
Indices
6 Central Limit Theorem
7 Confidence Interval
23
11 Multi-vari charts
12 Design of Experiment
13 Control Charts
14 Control Plan
Naresh Chawla,
Case Study
23
Naresh Chawla,
24
Naresh Chawla,
29
Naresh Chawla,
Problem Definition
Problem Statement:
26
Naresh Chawla,
Application of Tools
Tools Applied
Outcome
Fish-Bone Diagram
Testing of Hypothesis
Paired Comparison
Regression Analysis
Process Capability
DOE
27
Naresh Chawla,
Construction of
Hitch Control Valve
X2
D3
D2
X21
X22
X3, X4
X5
X6, X7
X8
Naresh Chawla,
DoE
Shortlisted Control Factors
Level 1
(Existing Level)
Level 2
(Proposed)
X1
Clearance (Bush-Spool) ()
10
X2.1
50.5
51.1
X2.2
50
49.8
X3
Spool Ovality )
No. of Factors
=4
No. of Levels
=2
Number of Blocks
Experiment replicated
29
Naresh Chawla,
Spool L/L
Point Ty pe
C orner
C enter
12
11
10
Mean
9
8
6
8
Sleeve H/H
10
49.9
50.0
50.5
50.8
Ovality
51.1
B
E
T
T
E
R
12
11
10
9
8
49.8
30
Solution
Clearance=6
SpoolL/L=51.1
SleeveH/H=49.8
Ovality =2
Naresh Chawla,
Changes in Manufacturing
Sleeve Honing
Sleeve cross holes
Radial grinding for Spool Valve
31
Naresh Chawla,
13
1st phase
12.7
12
2nd phase
11.3
11
10.3
USL 10
10.5
9.6
9.6
9.1
8.7
8.6
6.7
6.4
8.3
8.2
7.4
7.6
7.3
7.2
7.5
8.2
8.1
7.6
7.2
6.5
6.4
5.8
Design optimization
Trialbatchof20,16Feb14
5.8
5.9
5.8
5.3
5.5
5.1
5
4.8
3.6
3.9
1b
2b
3b
4b
5b
6b
7b
8b
9b
10b
11b
11b
12b
13b
14b
15b
16b
17b
18b
19b
20b
1a
2a
3a
4a
5a
6a
7a
8a
9a
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
26a
27a
28a
29a
30a
30a
5.1
5.1
4.3
32
8.3
1
2
3
4
5
6
7
8
9
10
11
12
11
12
13
14
15
16
17
18
19
20
12
13
21
22
23
24
25
26
27
28
Response(mm/3minutes)
8.5
Naresh Chawla,
In Plant rejection
9.4
8.97
10.6
9.12
7.66
8.8
8.65
6
3.37
2.35
3.98
4.9
4.5
3.61
3.78
2.76
63%
improvement
2.24
0.92
1.06
Feb
Jan'14
Dec.
Nov.
Oct.
Sep.
July
June
May
April
March
Feb'13
August
BEFORE
1.11
0.82
0.66
1.69
0.62
0.98
33
2.86
3.9
3.14
F15Q3
3.13
4.14
F15 Q2
4.19
March
3.81
5.6
F15 Q1
9.7
8.9
8.4
Better
60.5%
improvement
April
10
LR-RPH
12.5
12
AFTER
Naresh Chawla,
Benefits
Rejections at supplier end were reduced
52%.
34
Naresh Chawla,
Thanks
nkchawla@gmail.com
9779070555