Report

On
Online Summer Internship Programme
(OSIP-2020)

Lean 6-Sigma (6S)

Submitted in Partial Fulfilment of the Requirements for the mandatory Industrial Internship training
programme

Submitted by:

Dodiya Manharsinh Ranamalbhai

CHEMICAL ENGINEERING

MAHARAJA SAYAJIRAO UNIVERSITY OF BARODA, MSU

20th August to 7th October, 2020

Indian Institute of Chemical Engineers (IIChE)

Dr. H. L. Roy Building, Jadavpur University Campus,
188 Raja Subodh Chandra Mullick Road, Kolkata 700 032 www.iiche.org.in
/ [email protected]
 OSIP-2020
Certificate from the IIChE

This is to certify that Mr. Dodiya Manharsinh Ranamalbhai from Maharaja sayajirao University

of baroda has successfully completed online summer internship programme in our

organization. The matter embodied in this report is a genuine to the best of our knowledge and

belief and has not been submitted before, neither to this Institute nor to any other organization

for the fulfilment of the requirement of any course of study. During his internship tenure in

IIChE, we found him as a hardworking, sincere, and diligent person and his/her behaviour and

conduct was good.

We wish him all the best for his future endeavour.

Course Coordinator, OSIP-2020 Convener, OSIP-2020 Acknowledgement

The internship opportunity I had with IICHE OSIP-2020 was a great chance for learning and
professional development. Therefore, I consider myself as a very lucky individual as I was
provided with an opportunity to be a part of it. I am also grateful for having a chance to meet
so many wonderful people and professionals who led me though this internship period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude and
special thanks to Shri S D Karve, Mr.Rajagopal RJ and Mr.Hayavadana who in spite of being

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extraordinarily busy with their duties, took time out to hear, guide and keep me on the correct
path and allowing me to carry out my project at their esteemed organization and extending
during the training.

I express my deepest thanks to Mr.Dhawal Saxena, IICHE course co-ordinator for taking part
in useful decision & giving necessary advices and guidance and arranged all facilities to make
life easier. I choose this moment to acknowledge his contribution gratefully.

It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to Prof.
V.V. Basava Rao, President of IICHE and Dr. Avijit Ghosh, Convenor-OSIP 2020 for
providing such an impeccable programme and helping students in all ways possible.

Preface

Objectives of Online Internship Program

● Assist the student's development of employer-valued skills such as teamwork,

communications and attention to learn Engineer’s responsibilities and ethics.
● Enhance and/or expand the student's knowledge of a particular area(s) of skill.
● Expose the student to professional role models or mentors who will provide the student
with support in the early stages of the internship and provide an example of the
behaviours expected in the intern's workplace.

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● To familiarize with various materials, processes, products and their applications along
with relevant aspects of technology and troubleshooting.
● To gain experience in writing technical report/project.

Course Outcome

● Provides basic idea of different real life industrial processes, problems, trouble
shooting, decision making and preventive maintenance techniques and professional
culture of industry, work ethics and attitudes in industry. The different live situation,
trouble shooting and modern technological application.
● Provides course materials to the students for reference (in PDF format). The study
materials have been shared with the students through IIChE for its record.
● Improves to deal with the assignments which has been given for the solution /
conceptual ideas based on discussion during the tutorial classs.
● Helps to understand the importance of the application of modern tools for the industrial
automation / up-gradation / scale-up.
● Develops conceptual theory n the regular class room discussion and its application in
real-life industrial problem resolution.
● Gives primary idea to analyse Case studies based on real life application.

Content

1. Introduction 2. Discussion on different industrial Processes & applications 3.

Case study analysis (if any) 4. Scope of Research and development activity 5.
Summary 6. My observation / Opinion 7. Appendix: All assignments

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1. Introduction: Overview of the Industry

Introduction to Six Sigma

Six Sigma is a highly disciplined process that focuses on delivering near-perfect products
and services consistently. Its strength is that it is a continuous improvement process with
an unwavering focus on change empowerment, seamless training of resources and
continuous top management support. These three are known as the Pillars of Six Sigma. If
Six Sigma is implemented methodically, it will give sustained results for any process.
Now the question arises as to what is a process. This will be explained in the next screen. Process

of Six Sigma

Six Sigma follows a process called DMAIC (Pronounced as D-MAC). DMAIC stands for
Define, Measure, Analyze, Improve, and Control. Click each tab to know more. In the
Define phase, we define the problem statement and plan the improvement initiative.
Consider a typical problem in an Organization. A particular organization’s customers are
not satisfied with the current support process of the organization. You can define the
problem as the support process of the organization is at 20% satisfaction. In Six Sigma,
the projects are always defined objectively. In addition to defining the problem, the Six
Sigma project team is also formed in this phase. The Measure phase collects the data from
the process and determines the current quality and operational performance levels. Also,
the measurement criteria such as how to measure, when to measure, and who will
measure are established. In the Analyze phase, the business process and the data
generated from the measurement phase are studied to understand the root causes of the
problem. In the Improvement phase, possible improvement actions are identified and
prioritized. These are then tested and the improvement action plan is finalized. In the last
phase, which is the Control phase, the Six Sigma team goes for a full-scale
implementation of the improvement action plan and sets up controls to monitor the
system in order to sustain the gains.

List of DMAIC Tools

The list of DMAIC tools is discussed in this screen. There are specific tools used in each
phase of the Define, Measure, Analyze, Improve, and Control process. Later in this
course, important tools of each phase will be discussed. Click each phase to view the list
of tools. The define phase uses tools such as Supply, Input, Process, Output, Customer or
SIPOC (Pronounce as: sye-poc) Diagram, Voice of Customer or VOC (Pronounce as: vo-
c), Critical to Quality or CTQ Trees, Quality Function Deployment or QFD, Failure Mode
and Effects Analysis or FMEA, Cause and Effect or CE Matrix, and Project
Charter. The measure phase uses tools such as GAGE R and R Variables, Run Charts or
Control Charts, Cp, Cpk, Sigma level (Z Level) and Defects per Million Opportunity or
DPMO, and Anderson Darling Test. The tools used in the analyze phase are SimpleLinear
Regression or SLR, Pareto Charts, Fishbone Diagram, FMEA, and Multi-Vari Charts or

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Hypothesis Tests. In the improve phase,

the tools that can be used are Brainstorming, Piloting and FMEA, and Design of Experiments
or DOE (Pronounce as: d-o-e) (If needed). The control phase uses tools such as Control
Charts, Control Plan, and Measurement System Analysis or MSA Re-analysis. Note that
some of these tools can be used interchangeably between the phases

The generally accepted methodology for managing Six Sigma projects includes the following
phases:

Define: The objectives and scope of the project are defined. Relevant information about the process
and customer are collected.

Measure: Data on the current situation and process metrics are collected.

Industry/sector Six sigma implementation

● Improve effectiveness of a shell and tube heat exchanger.

● Reduction in the rejection rate of pump head of hydraulic jack set.

Manufacturing ● Reduce brush rejection rate in a bicycle chain manufacturing unit.

● Reduce of high rejection rate of the painted damper outer tube of shock absorber.

● Improve connecting rod manufacturing process.

● Optimize maintenance process for industrial system by using six sigma.

● Reduce level of defect in auto sectore manufacturing firm.

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• Enhance the FOQA methodology.

Aviation

• Minimize defects of maintain process in an aerospace company.

• Improve level of service in the departure area.

• Decrease waiting time of passenger.

4. Improve quality of service offered to the patients.

Healthcare 5. Reduce healthcare cost.

power 6. DM make up water reduction in thermal power plant.

Analyze: Collected data are analyzed to find the root cause(s) of the problem.

Improve: Solution(s) to the problem are developed and implemented.

Control: The implemented solution(s) are evaluated and the mechanisms are implemented to hold
the gains, which may include standardization.

DISCUSSION on different industrial Processes & applications

2. Discussion on different industrial Processes & applications

APPLICATIONS OF SIX SIGMA

Industrial process example:

Applications in fertilizer industry – Not many people are aware that the one of the most
potent Six Sigma techniques named as Design of Experiments (covered in detail in our
Black Belt training program) was first used in agriculture.

In the 1920s, Fisher created the statistical approach to Design of Experiments (DOE), and
the data analysis tool – Analysis of Variance (ANOVA), while working at Great Britain’s
Rothamsted Agricultural Experimental Station.

Design of Experiments was first used in a major way outside agriculture in the late 1940s and
early 1950s. Today the statistical approach to design of experiments is used in many areas
like manufacturing and R&D, sales and marketing, and service.

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One of the fundamental concepts in Six Sigma is – One should identify the critical
controllable input factors and then find the best combination of those for desirable output.
In agriculture, the quality and volumes of crop can be influenced by the use of best
combination of factors such as crop rotation pattern, spacing between seeds, fertiliser
selection etc.

Last few decades have witnessed a phenomenal increase in the fertilizer consumption in
many countries. As a result farmers and governments have stepped up efforts to expand
farm production to feed the growing populations and increase agricultural exports. The
major aim of these countries is to expand the agricultural output at a rapid pace as well as
to improve the overall quality of the produce. Six Sigma has a number of applications in
Fertilizers Industry which is an industry growing at a rapid pace across the world. IMC
Global, one of the Leading Fertilizer companies across the world has adopted Six Sigma
and is using it extensively to deliver high quality of products & services to its customers.
Six Sigma is used across the organization to improve and streamline procedures with an
objective to yield high quality produce. The company believes in “feed the land that feeds
the world”.

Six Sigma tools like ANOVA and DoE have huge applicability in Fertilizer Industry.
Using these tools, the impact of type and quantity of fertilizer variants on Crop Yield can
be studied. In India it will be critical to increase the produce/unit of land since the demand
for food is going up considerably. Moreover, the quality of produce is also increasingly
becoming a central theme with more and more people getting health conscious. This is the
right time to utilize the benefits of Six Sigma in the Fertilizer Industry

3. Case study

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Six Sigma Process Improvement Project

Project Name: Improving Acetic Acid Production

Process : Acetic Acid Production
Yellow Belt: 1. S Mohammed Mubarak
2. Jignesh A Suva
3. Dodiya Manharsinh Ranamalbhai
4. Indrajith Majumder
Six Sigma Leader: Dhawal Saxena
Master Black Belt: S D Karve and Rajagopal
DMAIC Steps
Deliverables

Phase
Define
SIPOC
Customers and CTQs established
Problem Statement, Business Case, Goals &
Scope
Team
Measur Key output measures Y identified
e Data Collection Plan
Do MSA (Gage R&R – Only for Black Belt)
Process Variation displayed (Span)
Baseline sigma performance calculated

Analyze Possible causes identified by Segmentation/Stratification

Detailed Process mapped in area of problem
Process Map Analyzed
Data Analysis – Root Cause validated
Vital Few identified
Opportunity is Quantified

Improve Solutions identified/mapped

Design Solutions
Implementation Plan – (Consider
Pilot)
FMEA executed
Cost Benefit Proposal Created
Control Standardized process
On-going Monitoring Plan established
Procedures/documentation realised
Response Plan developed and deployed
Systems and structures modified (staffing, training, reward and
recognition, systems)
Ownership of on-going process management transferred to process
owner
Define
 SIPOC
Region : Chennai Critical to Quality measure
Product / Service: Acetic Acid
Process : Acetic Acid Production PRODUCTION OF
No. of staff: 25 ACETIC ACID IN TONNES
PER DAY

IOCL, PTA Industries,

AXCEL Methanol & compressed Vinyl acetate
GASES, Methanol, CO sent to CSTR Acetic Acid Plants, Acetic
PETROCHEM carbon anhydride
ICAL monoxide Throttling valve Industries,
INDUSTRIES. MCA plants
Flash Tank etc.

Light End Distillation

Column

Purification Column

Packing
DMAIC Project Charter

TEAM NAME: CHEM GANG

Six Sigma Leader: Dhawal Saxena
Black Belt and Master Black Belt: S D Karve &
Rajagopal

●
●
●
●
High Level Improvement Timeline
Measure
Data Collection Plan Worksheet Key Output Measure Y

Production
Amount of
of Acetic
Acetic Acid By Excel Sheets, Team
Acid in Continuous 50 Samples Nil
Produced Per By Log Sheets. Members
Tonnes Per
Day
Day
Measure
Output Sigma
Understanding the Capability of the process

Define the following

CTQ: PRODUCTION OF ACETIC ACID IN TONNES PER DAY
Target: TO PRODUCE 125 TONNES/DAY OF ACETIC ACID BY FEBRUARY 29, 2O21
Defect: BELOW 100 TONNES PER DAY IS CONSIDERED AS DEFECT
Unit: NO. OF DAYS
Opportunity: 1

DPMO

You may need to do more than one sheet (or consolidate in a table) to show other Baseline calc’s or summary sigma.
Explain any sampling as appropriate. Hint: Update your problem and goal statements. Did they change based on your findings?
Measurement Data Display

GRAPHICAL SUMMARY OF DATA USING MINITAB

CONTROL CHART
Analyse
Fishbone Diagram/Cause & Effect/Ishikawa Diagram
Prioritisation of Xs: Control / Impact Matrix
Y=f (X1, X2, …, Xn)

Catalyst Quality, Irresponsible

Temperature, Workers, Poor Bias, Accuracy,
Pressure, Training, Outdated Limited Staff, Poor
Mixing, Reflux Ratio, Machines. Information, Set
Side Reactions, value correction.
Defective
Equipments.

Natural Government
Calamities Norms,
Environment
Conditions.
Narrow to Root Causes, Use Pareto Analysis
Vital Few Causes
2 1
9
Improve
Describe Solution(s) Selected

● Upgrading the Control System

● Optimisation of Temp, Pressure &
Temperature,Pressure and Reflux Ratio Reflux
● Adding Inert Material Heat Carrier in
the feed to increase the heat
capacity
● Recruitment of Highly Experienced
R&D Researcher for catalyst Selection.
Catalyst ● Catalyst Requirement to be cheap
and should have high selectivity and
Rate of Rxn
● Hiring of More efficient worker
● Organizing Training Programs for
Poor Information, Work Delay, every workers and testing their
Irresponsible workers consistency
● Strict Observation of the duty hours
of employees
● Repairing the valves
Defective Equipments ● Upgrading the control system
● Periodic Review of Equipments
Control
 Define the following
CTQ: PRODUCTION OF ACETIC ACID IN TONNES PER DAY
Target: TO PRODUCE 125 TONNES/DAY OF ACETIC ACID BY FEBRUARY 29, 2O21
Defect: BELOW 100 TONNES PER DAY IS CONSIDERED AS DEFECT
Unit: NO. OF DAYS
Opportunity: 1
DPMO
enter
1 Number Of Units Processed N = 50

2 Total Number Of Defects Made

(Include Defects Made And Later Fixed) D= 1

3 Number Of Defect Opportunities

Per Unit O= 1

4 Solve For Defects Per Million Opportunities

20000

5 Sigma will calculate Sigma=

You may need to do more than one3.55
sheet (or consolidate in a table) to show other Baseline calc’s or summary sigma.
Explain any sampling as appropriate. Hint: Update your problem and goal statements. Did they change based on your findings?
Control Summary
Thank You
 OSIP-2020
Scope of Research and development activity
FUTURE OF SIX SIGMA:

Six sigma is likely to remain as one of the key initiatives to improve the management
process than just being remembered as one of the fads. The primary focus should be on
improving overall management performance, not just pinpointing and counting defects.
Researchers and practitioners are trying to integrate six sigma with other existing
innovative management practices that have been around to make six sigma method even
more attractive to different organizations that might have not started or fully implemented
the six sigma method. Integrating and comparing principles and characteristics of six
sigma with Total Quality Management, Human Resource Functions, Lean Production,
ISO 9000, ISO 9001, the capability maturity model are all part of the quality
community’s effort to maximize the positive effect of the six sigma method.

ENGINEERING AND CONSTRUCTION SECTOR:

In 2002, Bechtel Corporation, one of the largest engineering and construction companies
in the world, reported savings of $200 million with an investment of $30 million in its six
sigma program to identify and prevent rework and defects in everything from design to
construction to on time delivery of employee payroll. For example, six sigma was
implemented to streamline the process of neutralizing chemical agents, and in a national
telecommunications project to help optimize the management of cost and schedule. The
objectives of implementing six sigma in R&D organizations are to reduce cost, increase
speed to market, and improve R&D processes. To measure the effectiveness of six sigma,
organizations need to focus on data driven reviews, improved project success rate, and
integration of R&D into regular work processes. One survey noted that as of 2003 only
37% of the respondents had formally implemented six sigma principles in their R&D
organization reported that the development and manufacturing of the new prototype at W
R Grace (Refining Industry) was cut to 8-9 months from 11-12 months by implementing
the DFSS process. Figure 4 shows the conceptual benefits and improvement of
implementing six sigma in R&D projects.

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Fig: Advantages of Applying Six sigma in R & D Projects

HEALTHCARE SECTOR :

Six sigma principles and the healthcare sector are very well matched because of the
healthcare nature of zero tolerance for mistakes and potential for reducing medical errors.
Some of the successfully implemented six sigma projects include improving timely and
accurate claims reimbursement, streamlining the process of healthcare delivery, and
reducing the inventory of surgical equipment and related costs. The radiology film library
at the University of Texas MD Anderson Cancer Centre also adopted six sigma and
improved service activities greatly .Also in the same institution’s outpatient CT exam lab,
patient preparation times were reduced from 45 min to less than 5 min in many cases and
there was a 45% increase in examinations with no additional machines or shifts.

MANUFACTURING SECTOR:

Motorola was the first organization to use the term six sigma in the 1980s as part of its
quality performance measurement and improvement program. Six sigma has since been
successfully applied in other manufacturing organizations such as General Electric,
Boeing, DuPont, Toshiba, Seagate, Allied Signal, Kodak, Honeywell, Texas Instruments,
Sony, etc. The reported benefits and savings are composed and presented from
investigating various literatures in six sigma.

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FINANCIAL SECTOR:

In recent years, finance and credit department are pressured to reduce cash collection
cycle time and variation in collection performance to remain competitive. Typical six
sigma projects in financial institutions include improving accuracy of allocation of cash to
reduce bank charges, automatic payments, improving accuracy of reporting, reducing
documentary credits defects, reducing check collection defects, and reducing variation in
collector performance. Bank of America (BOA) is one of the pioneers in adopting and
implementing six sigma concepts to stream-line operations, attract and retain customers,
and create competitiveness over credit unions. It has hundreds of six sigma projects in
areas of cross-selling, deposits, and problem resolution. BOA reported a 10.4% increase
in customer satisfaction and 24% decrease in customer problems after implementing six
sigma. American Express applied six sigma principles to improve external vendor
processes, and eliminate non-received renewal credit cards. The result showed an
improved sigma level of 0.3 in each case. Other financial institutions including, GE
Capital Corp, JP Morgan Chase, and SunTrust Banks are using six sigma to focus on and
improve customer requirements and satisfaction.

CONCLUSION:

Here through the implementation of six sigma tool in the project increased the Acetic Acid
Production from 100 tons to 125 tons per day. This gives the annual profit of 31 crore. This
lean six sigma reduces the waste and variation. The wastes are generally Factory inventory,
over production, over processing, Defects and Scrap, Transporting, Waiting, Movements etc.
These wastes are eliminated through lean implementation and the variations are reduced by
six sigma. Hence this lean six sigma tools helped us in making the process effective &
efficient and in turn increases the profit.

4. Summary

Six Sigma is a production philosophy that uses data, processes, and tools to nearly eliminate
defects and bring performance close to perfection. There are two different business strategies
basically Push and Pull. Push strategy is to push a product at a customer, while a pull strategy
pulls a customer towards a product.

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Six Sigma was introduced by American Engineer Sir Bill Smith while working at Motorola
in late 1980s.Six Sigma deals with Pull Strategy by taking a feedback from the customer and
then improving the quality of the product by applying different tools and approaches during
the process.
The main aim for any company is to satisfy their customers and produce QUALITY
products. Quality has been evolved over the years. We are now shifting to Contemporary
Pro-active Quality from historically, Reactive Quality. In Proactive Quality, we are basically
creating the process that will produce less or no defects.

Six Sigma is moreover a statistical approach where we take feedback from customers and
convert it to some measurable quantity.
We were then introduced to different tools to describe the data graphically which include:

▪ Stem and Leaf Plot

▪ Box and Whisker Plot
▪ Belt Graph
▪ Control Chart
▪ Polar Chart
▪ Quality Control Chart
▪ Snake Chart
▪ Biplot
▪ Ellipse Diagrams
▪ Cause & Effect Diagram (aka Fish Bone Diagram)
In Cause & Effect Diagram, we majorly classify the causes in 6 categories namely: -
Equipment, Process, People, Materials, Environment and Management. For a process, the
sigma value (z-value) is a metric that indicates how well or defect-free that process is
performing. The higher the sigma capability, the better.Sigma capability measures the
capability of the process to produce the defect-free outputs. Generally, defect is anything that
results in customer dissatisfaction. Six Sigma is a way of knowing where you are and where
you could be. It is a methodology of continuous improvement.

Six sigma is a road to achieve Zero defects, Quality Control and Total Quality Management.
Selection of Six Sigma Projects usually employs three different approaches namely Critical to
Quality (CTQ), Critical to Cost (CTC) and Critical to Satisfaction (CTS).

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DMAIC is the project methodology that is adopted for Six Sigma Projects. It consists of five
stages:-
D- Define M- Measure A- Analyse I- Improve C- Control

• In define phase, we clearly state the target business Problem and the scope of the
intended improvements. We also define the goal of our project here and map out what
success looks like.
• One primarily used tool for Define phase is SIPOC (Supplier-Input-Process-Output-
Customer).
• In Measure Phase, we put the data received from customers in the matrix form.

• Tools used in Measure Phase includes Process Flowchart, Data Collection, Voice of the
Customer Gathering etc.
• In Six Sigma process, main focus is given to the VOICE OF CUSTOMER (VOC).
Kano Model is used to describe VOC.
• Tree Plot is used to describe the customer’s needs into three categories Primary,
Secondary and Tertiary. The goal is to determine customer requirements based on Voice
of Customer Input.
• Later on, we discussed various voices that exist in any organisation namely VOB
(Voice of Business), VOC (Voice of Customer), VOE (Voice of Employee), VOP
(Voice of Process).
• In Analyse Phase, a root cause analysis is performed to determine the underlying
reasons for the business problems mentioned in the Define Phase.
• Different tools used in Analyse Phase includes Histogram, Pareto Chart, Scatter Plot
etc.

• In Improve Phase, we implement the proposed improvements in the process after

careful measurement and thoughtful analysis. Any risks associated with the
improvement should be identified before implementing it in the process.

• Various tools include in Improve phase are Brainstorming, Mistake Proofing,

Simulation Software etc.

• The final step in the DMAIC cycle is the Control Phase. It basically emphasizes that
successful improvements being employed in the process doesn’t degrade over time. At

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this stage, teams verify whether the improvement implemented has achieved the
projects goals or not.

• SIPOC (Suppliers, Input, Process, Output, Customer).

• Template of Project charter
✓ RESOURCE PLAN
✓ PROBLEM STATEMENT
✓ GOAL STATEMENT
✓ ESTIMATE FINANCIAL OPPORTUNITIES
✓ TEAM MEMBERS
✓ SCOPE
✓ CUSTOMER CTQ’S
✓ HIGH LIVEL PROJECT MILE STONE
• High level improvement timeline
• Measure phase
➢ CTQ
➢ MEASURE DESCRIPTION (OP DEFINITION) ➢ DATA TYPE
(CONTINUOUS / ATTRIBUTE) ➢ HOW MANY SAMPLES?
➢ HOW DID YOU COLLECT (USE ADDITIONAL SHEETS IF
NEEDED)AND BY WHOM ARE THEY COLLECTED
➢ SEGMENTATION CRITERIA
• DPMO = NO.OF DEFECTS * 1000000

(NO. OF OPPORTUNITIES) * (NO. OF UNITS)

• Measure Data collection
• Brief Graph summary from Minitab software or a simple bar chart
• Prioritization of X’s: Control/Impact Matrix
• After Measure phase tools , Analyse phase tools such as Cause /effect diagram or Fish
bone diagram / Ishikawa diagram, Pareto chart, Scatter Plot, Box Plot, FMEA risk
priority number calculations all those will be Done.
• Cause and effect diagram comprises of
➢ MOTHER NATURE
➢ MATERIAL

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➢ METHOD
➢ MACHINES
➢ MEASURES
➢ MANKIND (PEOPLE )

• After identifying the root cause for the Problem going to the implementation Phase
getting the solutions and Implementing & Monitoring in the Control Phase.

5. My observation / Opinion
Sigma is the symbol of standard deviation, a measurement of deviation of a sample from
the population average. Each sigma you depart from the average, the event, in this case
failure, becomes more an more improbable. At 6 sigma, the probability is about
3.5/million. But this is just the statistical side of Six Sigma. The bulk of the work in a Six
Sigma project would be in defining failures, measuring deviations, and other activities
which ultimately lead to product quality. In fact, Six Sigma is used as a term for a
management style, with the ultimate goal of high levels of customer satisfaction."

Six sigma is an effective and ubiquitous methodology to increase the production.It is

about how you gonna increase the production not only in industries ,markets or MNC's
but also in many daily routine activities .It mainly describes and contemplates about the
tools especially ( DMAIC .Define,measure,analyse, improve and control).and decrease
the percentage of defects or errors in respective projects.

There are many uses in the real world such as

Increasing production of useful chemicals,polymers,etc....

Declining the waiting time of patients in hospitals.

Increasing placement opportunities in various universities.

Increasing your productivity level in a day ( daily routine).

It was a productive and helpful online internship experience for me where i have got to
know many skills in 6 sigma

Moreover, Minitab is a statistical software package used for improvement in

statisticsbased projects. ... Minitab is a highly recommended statistical software by Six
Sigma professionals around the world. coming to minitab software ,I have learnt much
about the tools which are very useful for our project under yellow belt cerification .

Today, as a result of Six Sigma or similar approaches, many organizations are operating at
very high levels of efficiency. But as leaders now shift their focus to the acceleration of
growth, they are discovering that the very culture of little to no variance that allowed them

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to achieve their efficiency goals is suffocating their growth potential. Variance – dare I
even say error – is essential for innovation and growth.

Eliminating variation in a large organization can be a laudable goal, leading to profit and
efficiency. Yet variation is also not an obstacle to steadfastly avoid; it is a key to unlocking
your breakthrough future. Success requires embracing the alternative paths that markets
randomly present to us in order to find your organization– s own unique place to grow and
thrive.

Winning the quarter often requires the elimination of variance, but winning the long game
will require embracing it

According to me Future of Lean Six Sigma is bright if you use it judiciously. For example
over reliance of any system will result in few disadvantages. Lean Six Sigma may result in
operational efficiency of the business and it should be limited to that level. Coming to
business growth and innovation, LSS mind set may backfire.

6. Appendix: All the assignment

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Online Summer Internship Program-2020 (OSIP-2020) by
IIChE
SUBMITTED BY

Name of the Student: Dodiya Manharsinh Ranamalbhai

Year of study: B.E Final year

College/University: Maharaja Sayajirao University

Email ID: [email protected]

Mobile number: 7490084384

Assignment No: 1

Subject Code: 6-Sigma Batch-4 (6s4)

Topic of Assignment:

1) Project Charter:

It is an important tool used in defines stage. It consists of project name, problem statement,
Business case, scope, goal, timeline, team members, CTQ’s etc.

Example:

• Project name: Maximizing the Yield of Acetic Acid.

• Problem statement: Plant produces only 90 of yield of acetic acid and 10% of byproducts
of no value wasting the costlier raw material.
(problem statement the objective should be clear, concise and in measurable terms).

• Scope: To find out the route cause for the low yield.

• Goal statement: To produce 98 of yield of Acetic Acid.

• Business Case: Reducing the waste product efficient use of raw material.

• Estimated financial output: 50 crore

 • Timeline: you will be scheduling the time for the each phase in the DMAIC and you will
also enter the actual time taken to complete the each phase.
2)SIPOC
(process mapping)
It is another important tool of define stage helps in good
understanding of a process. Here,

s supplier, i input
feed, p process,
o output,
c customer.

Supplier: we will be entering who are supplying raw materials to our

industry.

Input: we will be listing the feed materials.

Process: we will be listing what are the unit processes involved.

Output: we will be entering what are the products that are produced.

Customer: listing who all requires the product that is produced.

Example:

Process name: Acetic Acid Production

Region: India

Suppliers Inputs Process Outputs Customers

1 Jamnagar Butane gas heater Acetic acid Pharmaceutical
Refinery industry ltd
2 Nayara Energy oxygen Packed bed Formic acid Polymer industry
Refinery reactor ltd
Energy seperation Propionic acid Vardhman textile
Ltd
 Cobalt acetate distillation Berger paints
catalyst
Food andbeverage
3) Ishikawa Diagram

Also called cause and effect diagram or fish bone diagram an important tool used in
Analyze Stage it tells what are the reasons that causes effect.

Ask why to get the causes.

5M 1P for categorizing the causes

FISHBONE DIAGRAM
Machine

Person Method

Corrosion of equipment Old method

Poor training
Defective equipments Side reaction

Lack information

Large size reactor Temperature,pressuere, no

Limited staff recycv

Varaiation in measuring conc. No efficient use raw Govt. norms

material

Impurities in feed Environmental cond.

Insert text here

cost Insert text here

Measurement
environment

Material

Example: low yield of Acetic acid due to the following causes

4) 6-3-5

It’s a brain storming tool 6 persons assemble together where three ideas are written by each for 5
minutes after 5 minutes paper moves to the next person.

Helps in collection of data within a short time.

With the use of brainstorming we discussed on the data collected and came with a idea of
intermitten removal of product to avoid by product formation.

5) CTQ’s

CTQ trees helps us to translate broad customer needs into specific, actionable, measurable
performance requirements. We can use this requirements to deliver high quality products and
services.

Need Drivers CTQs

 LEAN 6 SIGMA YELLOW BELT TRAINING REPORT

SUBMITTED BY:

Name of the Student: MANHARSINH RANAMALBHAI DODIYA

Year of Study: B.E final year

College /University: MAHARAJA SAYAJIRAO UNIVERSITY

Email ID:[email protected]

Mobile Number:7490084384

LECTURE NUMBERE: 1

Date of the lecture:02/09/2020

Topic of the lecture: introduction of six sigma

Lecture By: Prof. hayavandana

Time & Duration of the lecture:5:25 to 8:30

SYNOPSIS OF THE LECTURE:

Information of Process, Production system , VOC ,VOB ,VOP ,Various

Voices and Knowledge of white board learning and it’s terminologies like different
distribution

Terms & notation used in yellow belt

Origin of six sigma
How six sigma differs from lean
Application of six sigma
DMAIC knowledge

INTRODUCTION:

A process is a series of steps designed to produce a product and/or service as required by the
customer

Input (x) → process f(x) o → utput(y) effect

Highly capable process 6σ < (USL – LSL)
A Marginally Capable Process 6σ = (USL – LSL)
An incapable process 6σ > (USL – LSL)
Quality is defined as fitness for use
Q = P/E
Q=quality
P= performance
E= Expectation
 Coefficient of variation
CV=σ/µ
Motorola started experimenting with problem solving through statistical analysis later
know an six sigma programme
Six sigma → 99.97% defeet free
PDCA cycle
Act → plan
↑ ↓
Check ← Do

Application of six sigma

1) Unit operation

2) Unit process

DMAIC

Define → Measure → Analyze → improve → control

CONCLUSION:

In this lecture we learned about basic methodology and origins of six sigma and it’s
importance in industry .How it is useful for quality development and solved some examples Boxplates
with given data.

NEXT LECTURE:

Tools for six sigma yellow belt-part 1 by professor hayavandana

 TOOLS FOR SIX SIGMA YELLOW BELT TRAINING REPORT

SUBMITTED BY:

Name of the Student: Dodiya Manharsinh Ranamalbhai

Year of Study: Final year

College /University: Maharja Sayajirao University

Email ID:[email protected]

Mobile Number:9327433171

LECTURE NUMBERE:02

Date of the lecture:

Topic of the lecture: Tools for six sigma yellow belt part-1

Lecture by:Professor hayavandana

Time & Duration of the lecture:4:30 to 7:30

SYNOPSIS OF THE LECTURE:

What the purpose of stakeholder analysis?

To enlist the help of key organization players.

To gain early alignment among all stakeholders on goals and plans.
To help address conflict or issue early on.

How do you conduct stakeholder analysis?

Step 1: Determine who your stakeholder are

Step2: Group and prioritize these stakeholder
Step 3:figure out how to communicate with and win buy in from each type of
stakeholder

One of the example of how to do this is by using The power/interest grid and grouped into
four catogories

CTQ: In six sigma CTQ is an acronym that stands for Critical- to- Quality, CTQs are the
internal critical quality parameters that relate to the wants and needs of the customer.

Brainstorming Techniques Toolkit : Guidelines how to have better brainstorming

Brainstorming process in five step

Examine
Understand
Ideate
Experiment
Distill

SWOT ANALYSIS: The 4 parameters of swot matrix

Strengths
Weaknesses
Opportunity
Threats

CONCLUSION:

In this lecture we learned about basic methodology of tools of six sigma

Brainstorming techniques ,SWOT analysis etc use in problem solving

NEXT LECTURE:

Tools for six sigma yellow belt part-2

 TOOLS FOR SIX SIGMA YELLOW BELT TRAINING REPORT

SUBMITTED BY:

Name of the Student: Dodiya Manharsinh Ranamalbhai

Year of Study:Be final year

College /University: Maharaja sayajirao university

Email ID:[email protected]

Mobile Number:7490084384

LECTURE NUMBERE:3

Date of the lecture:16 September

Topic of the lecture: Introduction of six sigma tools and statistics

Lecture by: Prof. Rajagopal sir

Time & Duration of the lecture:5:30 to 7:00

SYNOPSIS OF THE LECTURE:

How can we benefit from six sigma?

Six sigma help us to develop that leadership skills

Six sigma help us to how can we look to the issues or a problem and solving those
problems using certain techniques

To balance two computing parallel imperative

Maintain current business operations

Transfer business operations in order to survive the

competition

The managerial aspects of six sigma and technical aspects of six sigma

CONCLUSION:
 In this lecture we learned about The managerial aspects of six sigma and technical
aspects of six sigma and also the benefits of six sigma
 LEAN 6 SIGMA YELLOW BELT TRAINING REPORT

SUBMITTED BY :

Name : Dodiya Manharsinh Ranamalbhai

Year of study : 4th.

College/University :Maharaja Sayajirao University

Email ID : [email protected]

Mobile number :7490084384

LECTURE NUMBER : 4

Date of the Lecture : 18.09.2020

Topic of the Lecture : Tools of Yellow Belt Part 2

Lecture By : Prof . Dr . J . Hayavadana

Time & duration of the Lecture : 5.00 to 8.00 (3 HR)

SYNOPSIS OF THE LECTURE :

• INTRODUCTION : The Yellow Belt Training generally covers the basic tools used in

Six Sigma. Some basic tools discussed during the Yellow Belt training are the SIPOC

diagram, Pareto chart, Various types of process Mapping, Histogram and other basic

statistics. Every tools has its own importance.

• The first topic which was discussed about “Cause and Effect Diagram” .

• There are four steps in cause and effect diagram

➢ The first step is Brainstorm possible causes of the problem.

➢ The second step is Classify the major causes under various headings.

➢ Third step is Draw a cause and effect diagram with the problem at the point of

the central axis line.

 ➢ The fourth step is Write the causes on the diagram under the classifications

chosen.

• Then he discussed some of the examples of the Cause and effect diagram.

• Next topic which was discussed about “ Regression Equations” and solved some

numerical problems.

• Next he discussed what is First Pass Yield.

• Next he discussed what is “Throughput Yield” and “ Rolled Throughput Yield”

• Next he discussed about Team Dynamics . There are five typical stages in the team

building process.

1. Forming .

2. Storming .

3. Norming .

4. Performing .

5. Adjourning .

• Next he discussed how to find “DPU” and “DPMO”.

• Last he discussed how to make a complete a Six Sigma project .

CONCLUSION : After the lecture we got the basic information about some Tools used in

Define phase and how it is used in the industry. We also got to know about different tools like

SIPOC, Cause and Effect diagram etc . The fourth lecture was very informative and we have

learned lot of new things.

NEXT LECTURE :

In the next lecture we will be discussing about “ Tools For Six Sigma”
 LEAN 6 SIGMA YELLOW BELT TRAINING REPORT

SUBMITTED BY :

Name : Dodiya Manharsinh Ranamalbhai

Year of study : 4th.

College/University : Sayajirao University

Email ID : [email protected]

Mobile number :7490084384

LECTURE NUMBER : 5

Date of the Lecture : 19.09.2020

Topic of the Lecture : Overview of DMAIC process & DEFINE process

Lecture By : Shri S D Karve

Time & duration of the Lecture : 5.00 to 8.00 (3 HR)

SYNOPSIS OF THE LECTURE :

• INTRODUCTION : The Yellow Belt Training generally covers the basic tools used in

Six Sigma. There are mainly 5 stages in six sigma . In this lecture mainly Define phase

has discussed.

• First topic which was discussed about Six Sigma methodology.

• Next he discussed about DMAIC roadmap.

• Then he discussed what is actual and observed process variation.

• Next he discussed how “Dabbawallas” served food 2 lakh people everyday without any

error.

• Next he discussed what is “7 QC Tools” .

• Then he discussed about Process Mapping.

 • Next he discussed what is “Stratification” .

• He also discussed how to collect data in Six sigma.

CONCLUSION : After the lecture we got the basic information about some Tools used in

Define phase and how it is used in the industry. We also got to know about different tools like

SIPOC, Process Mapping , Pareto analysis etc . The fifth lecture was very informative and we

have learned lot of new things.

NEXT LECTURE :

In the next lecture we will be discussing about “ Measure Phase”.

 LEAN 6 SIGMA YELLOW BELT TRAINING REPORT

SUBMITTED BY:

Name of the student: Dodiya Manharsinh Ranamalbhai

Year of Study:. 4th year

College /University:Maharaja Sayajirao University of Baroda

Email ID:[email protected]

Mobile Number:7490084384

LECTURE NUMBERE:6

Date of the lecture:27/09/2020

Topic of the lecture: Measure phase

Lecture by: Rajagopa sir

Time & Duration of the lecture: 5 to 8 pm

SYNOPSIS OF THE LECTURE:

measure phase, gist of six sigma, why process maping, types of flow
diagram, process map analysis, CTQS and CTPS, planning for data collection, what is data?,
variable data, craete new project qqq

INTRODUCTION

>Gist of six sigma

quality of inputs. quality of outputs. >>>>>depends on<<<<<quality of output (Y)

(x1,x2,x3). (x4,x5,x6)

>Process map is graphical presentation for:

a process as it actually operates (as is process map)

process start and end points (process boundaries)

making reworks and reparis obvious

>Key process output variables (KPOVS) or CTQS

>key process input variables (KOIVS) or CTPS

once we identified CTPS & CTQS next step is to:

develop a good data collections plan to measure CTQS & CTPS

a good data collection will have,what,which,where,and who about the data to be collected

>Brief introduction on six sigma geen belt project, productivity improvement in PET bottle
production line

CONCLUSION:

In this lecture we learned about gist of six sigma, process maping, brief about process map,
flow diagram, CTQS and CTPS and data collection

NEXT LECTURE :

SIPOC and project charter measure phase- data collection and case study by s.d.karve
 TOOLS FOR SIX SIGMA YELLOW BELT TRAINING REPORT

SUBMITTED BY:

Name of the Student: Dodiya Manharsinh Ranamalbhai

Year of Study: B.E final year

College /University: Maharaja sayajirao university

Email ID: [email protected]

Mobile Number:7490084384

LECTURE NUMBERE:7

Date of the lecture:26 September

Topic of the lecture: Sipoc and project charter-measure phase-data collection and case
studies by shri S. D karvw

Time & Duration of the lecture:5:30 to 8 pm

SYNOPSIS OF THE LECTURE:

what is test of hypothesis?

why hypothesis testing

various tests used for hypothesis testing

ANOVA-analysis of variance

non linear Regression analysis

logistics regression analysis

Value, value and non value added

different principle of lean

INTRODUCTION

>>ANOVA is powerful stastical analysis tool that can be used to compare means of three or
more populations
>>while this is called analysis of variance it actually compare means

>>logistics regression. analysis

+binary logistic regression

+normal logistics regression

+ordinal logistics regression

>>Definition :value

+ Noun:a fair return or equivalent of goods, services or money for something exchanged

+Relative worth, utility or importance

>>Principles

Identify value>>Map the value stream>>create flow>>Establish pull>>seek perfection

CONCLUSION:

In this lecture we learned about The hypothesis, various test on same , Anova is best
and value definitions and many more parameters.

NEXT LECTURE:

statistics and real time examples by rajagopal sir

 TOOLS FOR SIX SIGMA YELLOW BELT TRAINING REPORT

SUBMITTED BY:

Name of the Student: Dodiya Manharsinh Ranamalbhai

Year of Study: B.E final year

College /University: Maharaja sayajirao university

Email ID: [email protected]

Mobile Number:7490084384

LECTURE NUMBERE: 8

Date of the lecture:26 September

Topic of the lecture: Statistics and real time examples

Time & Duration of the lecture:5:15 to 6:30 pm

SYNOPSIS OF THE LECTURE:

What is the statics?

Statistics is way to get information from data

What is the data?

Data is record of actual observation

How many branches of statistics?

There are two type of statistics

1-Descriptive Statistics :

Measure central tendency, Standard deviation data set by graphically

2-Inferential Statistics:

Measure central tendency, Standard deviation data set by help of probability

distribution
 Introduction:

Concept of probability

Parameters and statistics

Population and sample

Concept of variation

CONCLUSION:

In this lecture we learned about basic statistics, branches of statistics, Concept of

probability and other parameters

NEXT LECTURE:

Statistics and real time examples

 LEAN 6 SIGMA YELLOW BELT TRAINING REPORT

SUBMITTED BY :

Name : Dodiya Manharsinh Ranamalbhai

Year of study : 4th.

College/University : Maharaja Sayajirao University

Email ID : [email protected]

Mobile number – 7490084384

LECTURE NUMBER : 9th

Date of the Lecture : 01.10.2020

Topic of the Lecture : Statistics and real time example

Lecture By : Rajagopal RJ

Time & duration of the Lecture : 5.15 to 8.15 (3 HR)

SYNOPSIS OF THE LECTURE :

• INTRODUCTION : Six sigma is a process that uses data and tools to remove defects

and bring the performance close to perfection . Six Sigma introduced by “Sir Bill

Smith” while working on Motorola in 1980. Six Sigma is moreover a statistical

approach where we take feedback from customers and convert it to some measurable

quantity.

• First topic which was discussed bout Hypothesis testing.

• Next he explained with the help of a example that the root causes of problem are real

or not.

• After this he explained what is Null hypothesis(Ho) and Alternate Hypothesis (Ha).
 • Next he explained the importance of P value. He said in Hypothesis testing we rejected

null when Risk is than 5 % (P<.05)

• Next he explained different hypothesis testing like T – test , Z – test.

T – test done when the sample size is less than 40 and Z- test done when the sample

size is more than 40.

• Next he explained T-test with the help of a glass manufacturing process.

• Then he explained ANOVA testing with the help of example of a paint manufacturing

process.

Conclusion : From this lecture I have learned lots of new thing like Hypothesis, ANOVA

testing, Null Hypothesis etc. It will help me lot in future to make a Six Sigma project.

NEXT LECTURE :

In the next lecture we will be discussing about “ Case Studies”

 LEAN 6 SIGMA YELLOW BELT TRAINING REPORT

SUBMITTED BY :

Name : Dodiya Manharsinh Ranamalbhai

Year of study : 4th.

College/University : Maharaja Sayajirao University

Email ID :[email protected]

Mobile number : 7490084384

LECTURE NUMBER : 10

Date of the Lecture : 04.10.2020

Topic of the Lecture : Case Studies

Lecture By :Shri. S D Karve

Time & duration of the Lecture : 3.20 pm to 6.30 pm (3 HR10 MIN)

SYNOPSIS OF THE LECTURE :

• INTRODUCTION : Six sigma is a process that uses data and tools to remove defects

and bring the performance close to perfection . Six Sigma introduced by “Sir Bill

Smith” while working on Motorola in 1980. Six Sigma is moreover a statistical

approach where we take feedback from customers and convert it to some measurable

quantity.

• First topic which was discussed about steps involved in Design of Experiment like

1. Define the objective.

2. Brain Storming .

3. Select standard DOE plan.

4. Run the experiment in random order.

 5. Collect data for all the relevant responses ..

6. Draw conclusion.

• Next he explained few terms used in experiments like Factors , Levels.

• Next he explained the Factorial design with help of Golf example.

• After this he discussed the Main effect plots and explained what should the optimum

setting.

• Next he explained the types of variation like Special cause and Common cause.

• Next explained how to select the control chart.

• If it depends on the volume two types of chart are there. For low production I-MR chart

and for high production X Bar chart.

• If it depends on the Lot Size there are 4 types of chart u-chart , p- chart ,c -chart, np-

chart.

• After this he explained Control Chart zone like Upper control and Lower Control Chart.

• Next he explained the case studies.

CONCLUSION : After the lecture we got the basic information of what is Design of
experiment and what is control Chart in Six Sigma and how it is used in the industry. In this
lecture he explained the case studies which will help us lot in future The last lecture was very
informative and we have learned lot of new things.