KPMG Lean Six Sigma The right place and the right time is here and now

Transcription

1 KPMG Lean Six Sigma The right place and the right time is here and now

2 Introduction In today s competitive business environment, there is much more emphasis on lean management, high quality, zero waste and continuous improvement. These are the cornerstones of Six Sigma professionals, who use this proven, data-driven approach, its methodologies and tools to achieve near-perfection in processes whether they re related to manufacturing products or delivering services. If you are considering earning a Six Sigma certification, then you ve probably wondered what a typical day in the life of a Six Sigma pro looks like. The short answer is that there is no typical day. Six Sigma practitioners come from every industry and from all levels of management. While there is no one right way to practice Six Sigma on a daily basis, there are general principles of the methodology that will shape the way that you see the people and processes that you work with.

3 Job Outlook for Six Sigma Professionals Six Sigma professionals continue to be in demand, as companies worldwide seek to cut costs and improve processes and decrease waste. Countless employers see hiring Six Sigma's as an investment that offers a high return because they know how to achieve more using fewer resources. Potential salary According to data published in May 2015 on national salary survey website, Salary.com, the median annual salary for Six Sigma Black Belts in the United States was $98,495. The middle 50% earned between $90,806 and $106,814, on average. The lowest 10% earned below $83,805, while the top 10% of earners in this category brought home upwards of $114,388. Glassdoor.com lists the Six Sigma Black Belt professional salary at $87,450. Salary.com also published data on top Six Sigma executive salaries. The median annual salary for this group, with at least 15 years of experience in the field, was $177,414. The middle 50% earned between $143,497 and $225,629, while the lowest 10% earned around $112,617 annually. The top 10% of earners in this category netted salaries above $269,526. Job Duties Six Sigma professionals are typically responsible for providing expertise in deploying Lean and Six Sigma programs and initiatives, and directing teams to achieve desired results using Six Sigma methodologies. Six Sigma professionals are typically responsible for providing expertise in deploying Lean and Six Sigma programs and initiatives, and directing teams to achieve desired results using Six Sigma methodologies. Six Sigma professionals support the analysis, planning, design, implementation and evaluation of key projects to help companies achieve their goals. Using Six Sigma methodology and analytics, they accomplish measurable business process improvements.

4 Benefits of KPMG Six Sigma to Your Career Learning Six Sigma and applying its methodologies to your work life can have tremendous impact on your future in business. Simply being able to put KPMG Lean Six Sigma Certification on your resume proves your commitment to improving your business acumen and analytical skills, not to mention your commitment to improving the business within which you work. In short, KPMG Six Sigma certification makes the recipient stand out from the crowd. That, in turn, can lead to better job opportunities and improved salary. It s not easy. Another reasons KPMG Six sigma certification demand so much respect is that they are not easy to attain, and executives and hiring managers at major companies know this. Then, of course, there are the practical applications. Those who know KPMG Lean Six Sigma are knowledgeable in dozens of different methods to reduce costs, increase revenue, streamline business processes and improve employee buy-in, all of which leads to a better bottom line. KPMG Lean Six Sigma training also prepares students for a leadership role. Once the Six Sigma Green Belt level is achieved, a person is not only educated on the methodologies of Six Sigma, he or she is prepared to become a change agent within their organization, leading efforts to improve processes and the quality of what is delivered to customers. Achieving KPMG Lean Six Sigma Green Belt status can open the doors for promotion into upper management, as well as improve your chances of obtaining a job with a different employer should you want to leave your current position. It s not difficult to see why a person with these skills and a KPMG Lean Six Sigma certification to prove it would be an attractive job applicant.

5 Electrical Engineering

6 Introduction All work is a process and Six Sigma focuses on improving processes, you can apply the principles to any industry. The tools used will vary depending on your position, but wherever there s a process, there s an opportunity to improve with Lean Six Sigma tools. This applies even if you are more on the creative end of engineering. The designing, testing, and developing side of electrical engineering might be considered more creative and less repeatable. However, there must still be best practices and approaches that produce consistent results by Six sigma

7 Benefits of KPMG Lean Six Sigma for Electrical Engineering Students KPMG Lean Six Sigma approach broadly defines how to accommodate power and the physical environment It Uses very simple data analysis that make it easy to understand manufacturing defects in electrical items It helps in generating interface between the electromagnetic device and the desired output. It helps in defining instrumentation design, description and specification including customer feedback on the most commonly encountered problems. Provides methods and techniques for testing and evaluating designs. It helps in Dealing with questions of electromagnets and its relation to equipment. It Covers correlation between electrical design and desirable output. It simplifies complex solutions and clarify difficulty levels. Solving Interference Problems in Electronics Engineers certified with KPMG Lean Six Sigma bring cost effective shows across operations to improve quality under limited resources.

8 Examples of six sigma Applicability in electrical Industry Reduce manufacturing Cycle time ( time to order to delivery) Improve customer service performance scores Reduce or optimize inventory levels Reduce scrap or cost of poor quality Reduce warranty cost reduce rejection due to design error Improve parts design process to meet specification 100%of times Improve parts reliability identifying & optimizing critical factors that ensures reliability Increasing coverage of products To Design the activity of Product Quality of the product Continuous improvement in process Product Quality improvement Determining units of defects Product testing strategy Control of variable process Some of sample project

9 Success stories

10 Skyworks Solutions - Six Sigma Methodologies Support Back-End Yield and Quality Metrics Improvement Introduction the Skyworks Wafer Fab Backend Core Team. The team has achieved backend process (post probe) yield increase of 3% per year for each of the last three years. Yield improvement activities also improve quality by reducing the PPM defective delivered to the downstream operations (the customer). Further, sustained yield improvement contributes significant cost savings. Define phase: Before starting on the road to visual yield recovery, it was imperative to understand the causes of yield loss. At that time, we were using HVI (human visual inspection) as the inspection method. There was significant operator-to-operator variation in the number of defects found. There was similar variation in the classification of the type of those defects. The combined variations led to a 15X uncertainty in the validity of the data. This information, combined with external reports on the repeatability and accuracy of HVI gave us the justification to purchase our first AOI (automated optical inspection) system. Measure Phase : Measure systems are established to automatically query databases and return yield performance reports to the engineering group on a regular periodic schedule. Customized reports are created within the MES system to investigate specialized relationships which might include process, tool, or operator effects on yield. Once the inspection recipes have been set up for AOI and integrated with the MES systems to capture the data, it is just a matter of time before volumes of data start streaming in (an engineers dream!). Analyze phase: This is probably the longest phase, and involves cooperation of the whole team to follow up on the actions suggested by the data. The data collected during the measure phase is used in conjunction with data analysis software to understand the extent of the extent of the problem, and in some cases to suggest solutions. Initially, two Pareto analyses were used to direct further in-depth analysis into the cause of yield loss. The first is a Pareto of causes of low yielding wafers; the second is a Pareto of defect categories. Improve Phase: During the improve phase, a separate six-sigma team might convene to address each of the high contributing items to the defect Pareto. This is decided on a case-by case basis, depending on the complexity of the problem. Control phase : One of the most effective methods of control is to establish yield control limits at the AOI step. If a wafer yield is below a minimum value, the wafer and/or process must be placed on hold for investigation. This allows for quick feedback and prevents an undetected problem from continuing Conclusion Six Sigma methodologies can be applied to the problem of visual yield to produce significant results. Further, sustained yield enhancement contributes significant cost savings, and improves customer quality

11 Implementation of Six Sigma in Crompton Greaves Introduction The company has made considerable progress towards integration of the Six Sigma methodology in its manufacturing processes with the ultimate aim of achieving 'Product Quality as Perceived By Consumer'. This methodology was actively pursued for 10 products for which Critical to Quality (CTQ) characteristics were identified based on market feedback. Regional team has also been trained in Six Sigma technology for capture of customer's voice. In addition to this, the company has also introduced stringent control measures with suppliers to ensure that inputs support the Six Sigma quality. In fact, all these measures have resulted in manifold improvement in the CTQs with substantial reduction in defects. Implication Phase I : Ten products have been covered in the first phase, while nine products would be included in the second phase. Increasing coverage of products with six sigma approach will progressively help the company achieve 'product quality as perceived by the customer'. Phase II: In accordance with plan, the second phase of Six Sigma implementation commenced during with increasing executives being trained in the methodology. Six Sigma methodology has been extended to the design activity of the products Conclusion The company has made considerable progress towards integration of the Six Sigma methodology in its manufacturing processes with the ultimate aim of achieving 'Product Quality as Perceived By Consumer & reduction in cost by 25% as recorded before. Improve % defect reduction in assembly line

12 Why KPMG as Six Sigma?

13 1. A professional 4-day training program offering six sigma green belt certification from KPMG 2. Only Program recognized across 147 countries where KPMG operates at 3. Successfully embraced by More Than professional globally 4. Delivered by Senior professionals From KPMG 5. With KPMG Six sigma you become a trained individual 6. Our deployment model is more cost effective than hiring a full time MBB in your Organization 7. Make yourself brand with KPMG Six sigma

14 Thank You