Body of Knowledge

• Overview of Six Sigma, DMAIC process improvement Methodology, Identification of improvement opportunities, Development of Project Charter, Mapping the Processes (SIPOC -Supplier, Input, Process, Output, Customer), Qualitative analysis of process maps,

• Voice of Customer, Identification of Critical To Customer/Critical To Business (CTQ/CTB) characteristics, Quality Function Deployment (QFD), Kano Analysis, Change management and Building effective teams, Business Risk Management

• Types of Data, Statistical distributions - Binomial, Poisson, and Normal; Graphical display of data – Histogram, Box plot, Dot plot, etc.

• Measurement System Evaluation for continuous variable data (Gauge R&R – crossed and nested) aswell as attribute data (Kappa Value, Kendall coefficient, Effectiveness, Miss rate, False alarm)

• Understanding variation - Special causes and Common causes, control charts for variables as well as attribute data, Normality test of data, and concept of confidence interval

• Evaluation of Process Capability, Initial and Ongoing Process Capability (Pp, Ppk/Cp, Cpk), and assessment of Sigma level, ppm/dpmo, Process capability ratio Cpm

• Stratification methods ( Pareto, Stratified Dot Plot, Stratified Scatter Plot, Multi Vari Charts, etc),

• Organizing for potential causes using cause-&-effect diagram, FMEA & Tree Diagram; Cause and

• Effect matrix, Verification/validation of causes using workplace (GEMBA) investigation, Why-Why

• Analysis, Fault Tree Analysis (FTA)

• Statistical models for validation of causes - Correlation and Simple linear Regression, Multiple Regression, Test of Hypothesis - 2 Sample ‘t’ and 2 proportion tests, Chi-Square, ANOVA one way, two way, General linear model and Nested ANOVA, Logistic regression model, Multivariate analysis – Factor, Cluster analysis​

• Sample Size determination for a given confidence level,

• Concept of Reliability and introduction to Weibull analysis, B10 Life. Time series analysis.

• Design of experiments (DOE) and details of full factorial and fractional factorial designs, Response optimization; Quality loss function and Taguchi methods of DOE

• Generate Improvement Ideas using Creativity Techniques, Solution Evaluation Criteria, Evaluation of solutions and selection of solutions, Change Management Process – Force field analysis,

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• Process of piloting the solutions and planning for full-scale implementation.

• Evaluation and Monitoring of the results after implementation of the solutions,

• Process management, Process of Closing and handing over the Project. Basic financial concepts to quantify the results

• Lean Concepts, Lean Metrics (Takt time, TCT, Value added efficiency) Value stream mapping (VSM), Lean tools such as 5S, Kaizen, Poke Yoke, Visual Workplace, Line balancing, one-piece flow, JIT, Kanban etc. Overview of Total productive maintenance (OEE, MTBF, MTTR, 16 Losses) and Value Engineering.

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OUTCOMES
At The End Of The Course, the participant will be able to

• Lead Lean Six Sigma Black Belt projects, in their organizations

• Apply advanced data analytics tools for problem-solving

• Take up leadership roles in their organizations

• Fast-track their career

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• He has over 33 Years of experience in the Automotive Industry having worked with Caterpillar
India, TVS group, and Western Thomson Group
• Qualified Six Sigma Master Black Belt from Indian Statistical Institute (ISI), Bangalore
• Completed Six Sigma Black Belt training in Singapore and obtained Black Belt qualification
from Caterpillar University
• Completed several improvement projects in the areas of Manufacturing Process
improvement, Warranty analysis, Cost Reduction, Setup time reduction, Lean Manufacturing
etc.
• Expertise in imparting Six Sigma training and guiding projects
• Conducted over 150 training programs on Lean Six Sigma, DOE, QFD, GD&T, SPC, MSA &
Other Quality Improvement techniques at Corporate organizations and Educational
institutions.​​

1. CNC Programming and Machining

• Duration: 5 Days (40 Hours)

• Cost: ₹18,000 + GST per person

• Highlights:

1. Real-time machining practice.

2. Hands-on experience with workpieces and tools in industry machines.

3. Techniques for maintaining tight tolerances using GD&T (Geometric Dimensioning and Tolerancing).

• Duration: 5 Days (40 Hours)

• Cost: ₹20,000 + GST per person

• Highlights:

1. Learn about electric vehicle (EV) structure and key component selection.

2. Understand EV component testing and design parameters.

3. Explore the Indian market and EV bike assembly.

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