#Bulletproof your Career with Lean Manufacturing and Six Sigma Methodologies

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Do you want to Bulletproof your Career? Mastering Lean manufacturing and Six Sigma methodologies is the way to go. This blog post is the road map to your success.

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Business excellence journey sustainable | Operational excellence journey

The billion-dollar question in Business Excellence Journey is, “is it sustainable”?.

The next question that follows is, which is the best methodology? TQM, TPM, LEAN, SIX SIGMA, TOC, AGILE, BPM?.

Related Article– Can we use best practices as a combination of Lean, TPM, TQM, Kaizen, Six Sigma?

After years of practical exposure to working with various organizations, we found the answer. We decided to share it with the rest of the organizations.

Seven Steps Business Transformation Systems was founded about a decade ago with the mission of Making Excellence a Culture.

We have developed a Seven-Step methodology to achieve and sustain Excellence. Two major factors that play an important role in sustaining Business Excellence Journey and its results are Leadership and Culture.

One of the great Business Gurus, Dr. Edward Deming said “The secret of success is a constancy of purpose”. If the Leadership believes in the long term and aligns & integrates all Business strategies under a single umbrella, success can be assured.

Otherwise, all tools become Flavour of the Month. Over the years, we have transformed several organizations in adapting best class practices and moving towards World Class Levels. The great news is most of them are sustaining the results and continuing the journey for years.

The mantra is very simple but it requires great commitment from the Leadership Team. That is the reason, we work only with those organizations where leadership demonstrates commitment and believes in Cultural transformation. It is a bit longer process like practicing Yoga without side effects! We tell this fact upfront and only after the acceptance and understanding about the way Excellence work, we proceed to the next step. Each organization is different; so our road map also is customized based on the challenges faced by the organization.

For Example, if the overall Lead-time to delivery is too high, Lean methods will help and if the consistency process or results is a problem, six sigma tools will help. Most importantly, if an organization has no set vision, mission, and strategies, Hoshin Kanri is the best tool.

So a combination of several methodologies blended and a customized business excellence model is created for each aspiring organization. Our first step before accepting any assignment is“Initial diagnostics (in the form of assessment)and feedback”.

Related Article– Bulletproof your career with Lean manufacturing and Six Sigma methodologies

We suggest certain principles to be embraced and strictly followed based on our initial study. Once Leadership agrees to the Principles and recommended model, the journey begins Seven Steps Business Transformation Systems Established in 2012 provides Business Excellence Solutions in the areas of Manufacturing, Service, Construction, Education, Infrastructure, IT, Governance and Healthcare. The Company is managed by professionals who have vast industry experience and passionate about Business Excellence. Expertise includes Business transformation Strategies, Balanced Score-card, Policy Deployment(Hoshin Kanri), TQM, TPM, Lean, SixSigma, Quality Management Systems, Business Process Improvement, and Environment & Safety Management Systems. It has other verticals to complement its vision.

Seven Steps Academy of Excellence provides world Class training and certifications. Bexsolutionz division supports Visual Workplace standards. SME division provides world-class services for excellence for aspiring and committed small and medium businesses. Seven Steps developed unique Standard for 5S called SSAOE-A5S-10 and certifications awarded to organizations after stringent assessment. Seven Steps offers special packages to Micro. Small Scale Industries as a part of its CSR initiative. A 100 crore club is created with a vision of transforming 100 Micro and Small Scale Industries to 100 Crore companies by 2025.

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Bulletproof your career with Lean manufacturing and Six Sigma methodologies

There used to be a time when certain jobs are considered as dream jobs and highly respected such as Telecom new connections and ticketing clerk in a reservation counter, teller in banks. These were all niche jobs and posts. What happened to those jobs?  Are they still in demand or the demand has reduced?  Many of those who did not want further learning or skill enhancement were left behind as clerks with same pay or lost their jobs.

Similar things happen in many industries where the job role becomes obsolete.  Many people declare their experience in their resume.  If some has learned a job in one year and got mastery over it and continued in the same job for 25 years, it does not mean that he has 25 years experience.  It is equivalent of one-year experience only. This implies that if within two years, if they do not eliminate their job and move on with a new job profile or new field, the person is bound to be outdated.   There is a wide difference between “being efficient” and “being effective”. As the old thought says, efficiency is climbing the wall faster. Effectiveness means, finding the right wall and climbing fast.  As per Toyota production system or Lean Manufacturing methods, a tortoise can be more effective than a rabbit in covering distance faster.

Contrary to the old way of thinking of highly skilled in one job and zero skill in other job, Toyota way of thinking calls for multiskilling and inherent abilities.  Higher job roles also needs knowledge in multiple domains and functions.  For example if some one joins Quality department in early career, they are expected to learn Lean manufacturing methodologies also which support Quality. They cannot say that my job is in Quality department and why should I handle production related problems. In the same way, if some one in production department should also know problem solving skills, 7 QC tools, process capability, Six Sigma methodologies.

In automotive sector, a traditional welder is replaced by a high performance Robot which also means de-skilling the job elements. If the welder feels that he wants only welding job and does not learn any further or jumps to another job where welding is manual operation, he is struck as welder in his full lifetime.  Welder should upgrade his skill further to next higher level of ability to programme the robot or becoming a Lean planner who can improve material flow through Value Stream improvements. That way, he can be upgraded to a better job profile. It is high time people understand the need for their skills relevant in constantly changing market requirements.

There is a recent threat in Automotive industry for converting petrol, diesel vehicles to electric or hybrid vehicles.  This again calls for adapting and reskilling of people across the functions to be ready to embrace drastic change in their product portfolio. Everyone should be in a position to leave the old technologies and adapt newer technologies.  Continuous learning culture will enable every one to learn every day.

Those organizations who embraced and consistently implemented concepts such as 5S, Lean manufacturing, Total Productive Maintenance and Total Quality Management and Six Sigma in their current working culture have demonstrated the ability to learn any thing new and move on.  This also helps in improving attitude, respect for people which also helps in adapting their jobs in any new upcoming industries and sectors.  If one is specialized in automotive in the past, they can easily move to Aerospace industry or food industry.  If some one is experience in the past with mass production or high volume production, they will know how to adapt themselves with high mix and low volume production.  They will be more adaptable to change due to their confidence in handling any situation and due to having knowledge of key principles of Lean manufacturing.

Seven Steps Academy of Excellence is helping individuals and organisations in skill development through various training modules and courses such as Applied 5S training, Six Sigma Green Belt Training, Six Sigma Black Belt Training, Problem Solving Tools and Techniques, Policy Deployment , Daily Work Management Systems, Kanban supermarkets.

We can support organisations in skill development of their employees through inhouse training programmes and customizing to the needs of the specific industry.

As part of college to corporate initiative, Seven Steps Academy of Excellence also offers specialized skill development programmes to Students to improve their employability through finishing school.

Seven Steps Academy is one of the best training centers to get trained in Lean and Six Sigma. The faculties are really knowledgeable, and they make you learn with their experiences. Myself after completing the training decided to work in this domain in future. They also give tips on how to pass the exam from ASQ. if you want to become a complete Lean Six Sigma professional, do the course from ASQ and Seven Steps Academy and pass the exam and get certified.

- Deepak K S

Seven Steps Academy in association with Karnataka German Technical Training Institute Bangalore (KGTTI- A Govt. of Karnataka initiative) offering this unique program and all the practical sessions of the same will be conducted at the state of the art facility of KGTTI Bangalore campus.

After successful completion of the program deserving candidates will get immediate placement as Trainee Engineer in a precision manufacturing industry.

Automobile Engineering

Course Duration : 8 Weeks (320 Hrs)

Eligibility:

Career Opportunity in Fresh B.E / B Tech in Mechanical / Production

Design, Planning, Sourcing, Production,Quality, Maintenance, Sales & Service etc.

Industry Segments

Automotive, Aerospace, General Engineering,

Energy, Defence, Electronics, Machine &Cutting Tools, Mining & Construction

Equipment and Tooling Industry etc.

College to Corporate

Increased rate of corporate placements.

Satisfied students and parents.

Cut above the rest and create a benchmark above other colleges.

Contribution to society by producing high performing human resources.

Benefits to the Academic Institution

Course Curriculum in Brief

Precision Manufacturing Industry-an overview

Corporate culture- basic etiquettes and expectations

Behavioural and Leadership Skills

Introduction to Engineering Drawing

Geometric Dimensioning & Tolerancing

Various Manufacturing Process

Basics of Metal Cutting

Machine Tools- Cutting Tools- Fluids

Introduction to CNC machines

CNC Operation & Programming

Process Planning & Control

Cost Estimation, Time Calculation

Metrology and Measurements

Heat treatment & Surface Treatment

QA & QC and Quality Practices

Introduction to 5S, KAIZEN, Lean, Six Sigma methodologies

For your requirements of skill development and inhouse training programmes, please get in touch with us.

Seven Steps  Academy of Excellence is Learning and Development arm of Seven Steps Group ( A business excellence focussed organization) dedicated to Research, Training and Development in the area of Leadership, Quality and Business Excellence. Academy offers around 15certification programs and more than 100 experiential learning modules in the areas of Lean, TPM,TOC, TQM , Quality Management Systemsand Six Sigma. It also provides Industry specific and approved  training programmes for Engineering, Automotive, Retail, Aerospace, Healthcare, Hospitality, IT and Process Industries.

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There used to be a time when certain jobs are considered as dream jobs and highly respected such as Telecom new connections and ticketing clerk in a reservation counter, teller in banks. These were all niche jobs and posts. What happened to those jobs?  Are they still in demand or the demand has reduced?  Many of those who did not want further learning or skill enhancement were left behind as clerks with same pay or lost their jobs.