This document discusses how Six Sigma can be applied across various industries to improve processes and reduce costs. It provides examples of successful Six Sigma applications in industries like automotive, manufacturing, IT, and telecom. Specific areas of improvement include reducing defects, increasing productivity and sales, and saving costs. Engineering disciplines like mechanical, electrical, and IT help contribute to Six Sigma success. The document also outlines benefits students can gain from learning Six Sigma and how it complements their engineering and management studies.

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Presentation by
Benchmark Six Sigma

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 To show applications of Six Sigma in various
Industries.
 To highlight the linkage of Engineering and
Management Studies to Six Sigma application

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• Helps organizations produce products and services better, faster and
cheaper.
• Remove Wastage
• Maximize Customer Satisfaction
• Maximize Product/Service Quality. (Develop Close to Zero Defect
Products/Services)
• Increase Sales
• Increase overall Organizational Productivity
• Save Costs
• Make the Organization a Data-driven organization
• Faster Cycle Time
• Empower Employees

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Organizations have successfully benefitted from tools and concepts
that are covered extensively in Six Sigma for decades. Some examples
are :
• Statistical Process Control which uses Control Charts
• Total Quality Management
• Process Management through Measurements of outputs
• Project Management
• Application of Statistical concepts like Hypothesis testing, Regression Analysis
and Design of Experiments
However, Benchmark Six Sigma has packaged these tools (through
Green Belt, Black Belt and MBB programs) in a manner that makes
it many times more powerful

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Six Sigma is a “Industry Independent” methodology and has been
successfully applied across:
• Manufacturing Industry including Automotives, Aerospace, Health Equipment,
FMCG, Electronic Goods, Continuous Process Industries, Textiles, etc.
• Service Industry including Telecom, Banking and Financial Services, Health
Care, Hotels, IT, ITES, KPOs, Airlines, Cargo movement, Support Services, HR
services, Marketing Services, etc.
• R&D organizations or in R&D functions of various organizations

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Company Annual Savings
General Electric $2.0+ billion
JP Morgan Chase *$1.5 billion (*since inception in
1998)
Texas Instruments $600 million
Johnson & Johnson $500 million
Honeywell $600 million

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• Six Sigma Methodology has been successfully applied in all Industries
• Benchmark has had the opportunity to train close to 6000 persons from all
Industries
• Based on the combined experience of Benchmark Consultants, next few
slides show the areas in which Six Sigma has been successfully applied
in some of the Industries we have worked with (a sample).
• We shall also look at select companies in each Industry that have
successfully applied Six Sigma
• We would also see which Engineering specializations have contributed to
success in the highlighted areas

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Industry Examples of Six Sigma Applicability
Automotives i. Enhancing Supplier Quality
ii. Improving Safety & Reliability of Finished Vehicles
ii. Reducing Manufacturing defects at each stage
iv. Using Design FMEA to understand and prevent any possible design failures
v. Reducing variation in all the critical parameters that impact the finished product
vi. Improving the overall Incoming Material Quality or parts Quality
vii. Optimizing Inventory levels for all major parts
viii. Reducing time to manufacture
ix. Reducing Design defects
x. Reducing Supplier Lead time i.e the time take by each supplier to deliver goods
xi. Improving First time yield and efficiency of each step in the Manufacturing
assembly line.
Few Examples of Companies: Tata Motors, Ford, GM, Maruti, Telco.
Engineering Specializations who contribute : Mechanical, Electrical, Engineering
Design, Computer Science, IT

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Industry Examples of Six Sigma Applicability
Continuous Process
Plants
i. Improving overall Yield of each shift
ii. Reduce scrap or spilled materials
iii. Reduce the Process failures or breakdowns
iv. Increase Plant capacity utilization
v. Improve Operator Productivity
vi. Reduce time to restart the process after failure
vii. Create mechanisms to prevent failures at each stage
viii. Improve overall process stability & control
Few Examples of Companies: Reliance Industries Ltd, Asian Paints, GE plastics,
Wipro consumer goods
Engineering Specializations who contribute : Chemical, Mechanical, Electrical, IT,
Product Design and Engineering Design

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Industry Examples of Six Sigma Applicability
Engineering Parts
Manufacturing
i. Reduce Manufacturing cycle time (time of order to delivery)
ii. Improve Customer Service performance scores
iii. Reduce or optimize inventory levels
iv. Reduce scrap or cost of poor quality
v. Reduce warranty costs
vi. Reduce rejections due to design errors
vii. Improve parts design process to meet specifications 100% of times
viii. Improve parts reliability by identifying & optimizing critical factors
that ensure reliability
Few Examples of Companies: Gates India Ltd., Medium to small scale suppliers of parts
Engineering Specializations who contribute : Mechanical, Electrical, IT, Product Design
Engineering Design, Electronics and Communication, Computer science

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Industry Examples of Six Sigma Applicability
Textiles/ Fashion
houses/ Garments
i. Eliminating manufacturing errors/defects
ii. Improving first sample approval percentages while working with
buyers
iii. Improving buyer satisfaction levels
iv. Increasing repeat business
v. Improving supplier evaluation processes
vi. Improving processes at the source (including fabric purchase and
inspection, stitching, embroidery, packing and shipping) to reduce
rejections at later stages.
vii. Reducing costs
viii. Reducing delays
Few Examples of Companies: Reliance Industries, Raymonds, Grasim
Engineering Specializations who contribute : Mechanical, Electrical, IT, Product Design
Engineering Design, Electronics and Communication, Computer science

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Industry Examples of Six Sigma Applicability
Information
Technology
:Software
development
i. Reducing the overall Software development times
ii. Reducing the number of errors found during product usage
iii. Improving the estimation process to reduce time and cost overruns
iv. Improving the requirements gathering process to reduce rework
v. Reducing complaints resolution time
vi. Creating systems to detect defects early in the process (to reduce high costs
associated with defects identified later)
vii. Reducing appraisal cost per defect by phase and appraisal type (by project and in
total)
viii. Reducing rework (All work done to fix an application after it has been delivered to
a customer is rework. This includes corrections to features or functions that are
incorrect, and also may include "missed requirements" - things the customer
expected but did not receive.
Few Examples of Companies: TCS, Infosys, IBM, HP, Patni, Birlasoft
Engineering Specializations who contribute : Computer Science, IT, Electronics and
Communications mainly. All other branches of engineering for specific domain application.

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Industry Examples of Six Sigma Applicability
Telecom i. Improving ARPU (Average revenue per unit)
ii. Reducing Billing errors
iii. Reducing timeliness of billing
iv. Improving the Call Completion rate (i.e Network Quality)
v. Reducing network congestion
vi. Development of new features, processes for new services
vii. Improving accuracy, timeliness and completeness of new connections
viii. Improving accuracy, timeliness and completeness of customer communication.
ix. Reducing Customer churn
x. Reducing network congestion
xi. Improving call routing procedures
xii. Improving sales productivity
Few Examples of Companies: Bharti Airtel, France Telecom, Reliance Infocomm, Siemens
Engineering Specializations who contribute : Telecom , Electronics and Communication, Product
Design , Computer Science, IT

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Industry Examples of Six Sigma Applicability
R&D/ Product Design i. Reducing the time to market
ii. Reducing rework through synergy between R&D and the customer
facing staff.
iii. Improving the overall performance & quality of product from start
iv. Minimizing product failures by ensuring robust designs
v. Improving quality of research process & experiments by providing
mass education in Experimental design and Multivariate studies
vi. Improving quality of design reviews (data driven reviews)
vii. Reducing defects in final product thereby saving on warranty costs.
Few Examples of Companies: GE Labs, Boeing, Agilent Laboratories, Motorola,
Microsoft, Semiconductor Industry
Engineering Specializations who contribute : Product Design, Electronics &
Communication, Computer Science, IT and others depending on type of application
designed

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 Gains knowledge about the Engineering/ Management
Disciplines and applications from the text books
 Engineering - Learning about Engineering concepts,
applications, working in laboratories, running
experiments & drawing inferences, understanding kety
elements for technical success.
 Management – Learning about Management concepts,
applications, business organization, strategies,
functional areas, understanding key elements for
business success.
 Getting exposed to number of mathematical and
statistical models as part of course

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 After undergoing Six Sigma training:
 Understands how engineering and/or management
knowledge can be applied to make an effective
contribution in an actual organizational environment.
 Supplements technical skills learned during
Engineering with practical knowledge
 Can take up Summer Internship Project as a small Six
Sigma Project
 Utilizes Six Sigma knowledge as a competitive advantage
in the job search and career progress.

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1. Message for Students pursuing full time professional courses.
 Is Six Sigma a suitable additional learning for students? Why? How does it
help?
2. What is Six Sigma?
 What are the key ideas in this methodology? Why is it so successful?
3. Function specific applications of Six Sigma
 Which functional areas have Six Sigma applicability?
4. Six Sigma personal success stories
 How people have succeeded with Six Sigma? What are their success stories?
5. Six Sigma corporate success stories
 Which companies have benefited? Sample benefits?
6. About Benchmark Six Sigma
 Who is Benchmark Six Sigma? What are the Services? Who are their clients?