TCS Mapping Six Sigma in client’s process

1. TCS Mapping Six Sigma in client’s process

2. TCS – An Introduction Largest software IT and management consultancy Staff strength of over 70,000 Revenue of US $ 4.3 bn in 2006-07 Tata Research Development and Design center ISO 9000 certification across 95% of the company in 1995

3. ……contd • Software Engineering Institute’s ( SEI ) Capability Maturity Model • About SEEPZ • About Chennai

5. Product Engineering Practice • Delivers end-to-end solutions • > 1500 consultants • Over 6000 person-years of experience • High end consulting expertise 1. Automotive 4. Marine Engineering 2. Aerospace 5. Transportation 3. Heavy Engineering

6. TCS practise Six Sigma for some client’s process 6σ-An Introduction • Founded by Bill Smith at Motorola in 1986 • Inspired by quality control, TQM and Zero Defects

7. …..contd Registered service mark and trade mark of Motorola Inc. Motorola saved US $ 17 bn Practiced by BA, Caterpillar, HI, GE 3M, Merry Lynch 2 key methodologies – DMAIC & DMADV inspired by Demming’s cycle

9. ….contd TCS adopted 6σ initiatives ( not yet a six sigma company ) in 1998. > 350 trained six sigma technology consultants

10. Why SIX SIGMA ? Reduces costs by 50% or more Reduces waste chain. Better understanding of customer requirements. Improves delivery and quality performance. Provides critical process inputs Develops robust products and processes Drives improvements rapidly with internal resources.

11. How much is TCS capable for its implementation? • Over 350 experienced Six Sigma consultants • 260 Certified Green Belts, 12 Black Belts and a Master Black Belt • 400 Six Sigma projects completed. • Quality Standards • Six-Sigma • SEI-CMM • ISO 9000 • Tata Business Excellence Model (Based on Malcolm Baldridge-Award) • Specialized training programs • Domain experts

13. Where will TCS implement six sigma ? Service Offerings • Six Sigma for Organizational Business Process Improvement • Six Sigma for Product Quality Improvement • Six Sigma Consultancy for Services • Engineering Services • Architecture & Technology Consulting • E-Security • E-Business • Infrastructure Development and Management

14. Results Six Sigma Projects completed in the areas of • Cycle Time Reduction • Defect Prevention • Productivity Improvement • Process Refinement • New Process Definitions • Design Optimization of Products

15. Our Objective To study implementation of six sigma process in OEDC (Offshore Engineering Development Center), Chennai for General Electric corp.

17. In 1998 - 1999 OEDC carried out 4 six sigma projects Schedule compliance and product quality compliance 4 phases – MAIC (Measure, Analyse, Implement, Control) Center Managers, Project Leaders, Quality team and all team members participated. Undertaken for 2 GE business teams.

19. 1st step – Measurement Process mapping to reduce variability, time & cost Identification of key input and output variables at every step Objective – To eliminate non-value-added process steps, bottlenecks and re-work process.

20. Input variables which affect CTQ such as schedule compliance & quality compliance were identified Process Variables : Schedule Compliance • Estimates • Realistic estimates • Input Study • Project Management • Effective project tracking and Monitoring • Fixing up priorities • Resources management • Input Quality • Clarity and completeness • Conformance to standards

21. Process Variables : Product Quality Knowledge • Product • Standards Input Quality • Clarity • Conformance to Standards Estimates • Estimated time Tight schedules

22. 2nd step - Analyse • Cause & effect Diagram - To isolate key problem areas - To study the variance from the ideal performance - To identify relationship between variables.

23. Cause and Effect Diagram

24. 2nd step - Analyse • Cause & effect Diagram - To isolate key problem areas - To study the variance from the ideal performance - To identify relationship between variables. • Process Failure Mode and Effect Analysis (PFMEA) - To identify ways in which project can fail - To estimate risks - To evaluate current plans

25. 3rd step – Improvements • For the Process improvement, the following were introduced… - Process controls - Error Proofing/ Productivity Tools • Management actions to prevent failure causes

26. Improvements carried out by TCS • MANAGEMENT ACTIONS • New Facility • New Hardware • PROCESS IMPROVEMENTS • Procedures • Guidelines • Error Proofing • Tools • Productivity Tools • PROCESS CONTROLS • Project Review • Meetings • Causal Analysis • Internal Audit • Compliance • Monitoring

28. 4th step - Control • To assure six sigma spread would fit within limits of specifications ( Process capability study) • To draw normal curves for CTQs and make decisions about capability of the process ( Process generated data)

29. On-time delivery and Product Quality Normal Curve Charts

30. On-time delivery and Product Quality Control Charts

31. Trend charts for schedule compliance and quality compliance

33. the end..