This project report by Sachin Pandit explores applying lean and six sigma methodologies to the filmmaking process to reduce costs and improve efficiency in Marathi cinema, aiming for a 25% reduction in efforts without compromising quality. The document outlines various stages of production, critical factors affecting costs, and suggests systematic approaches to eliminate waste and enhance productivity. It highlights the importance of collaborative efforts and detailed planning in managing film production costs and enhancing creative outcomes.

1. A PROJECT
REPORT ON
APPLYING LEAN AND SIX SIGMA APPROACH FOR FILM MAKING PROCESS TO
REDUCE EFFORTS AND COST
Submitted By: Sachin Pandit
MBA – Media & Entertainment
IVth Semester – Oct 2015
Register Number: 14297603
BHARATHIDASAN UNIVERSITY

2. Table of Contents
• Declaration
• Certificate from company
• Background and objective
• Company profile
• Problem statement
• Project benefits and expected outcome
• Research methodology
• Process flow diagram

3. Table of Contents…cont..
• Stakeholder matrix
• Cause and Effect matrix
• Failure mode effect analysis
• Critical inputs
• Conclusion and redesigned process
• Usage
• References

4. Declaration
I, Mr. Sachin Pandit
hereby declare that this project report is the record of authentic
work carried out by me during the period from Aug 2015 Oct 2015 to and
has not been submitted to any other University or Institute for the
award of any degree / diploma etc.
Signature
Sachin Pandit
Date – 23-Oct-2015

5. Certificate

6. Background and objective
Film making is a costly affair. There is no direct formula for success of the film. Success can be measured
in terms of appreciation and in terms of Box Office collection. In regional film industry there is a
constraint on viewers, which is limited to urban and rural area of particular region. To make the film
business profitable is has become necessary to produce the film within budget and cut the unnecessary
costs.
Lean and Six Sigma are proven methodologies for waste elimination and process improvement with
reducing the variation. I am practicing Six Sigma since last 6 years and into film making business. I
thought of applying the Lean and Six Sigma knowledge to Film making process and laydown some rules
which will help producers, film makers to control their cost, select correct resources and so on.
In this project I will apply this methodology for film making process of Marathi Cinema

7. Company Profile
Vedarth Creations is an arm of Innovact Solutions which is focused on Film Making. The team ‘Vedarth
Creations’ have all capabilities required for Film making, which includes Scripting, Direction, Production,
Music, Editing, and special effects. Since 2012 this team has worked on various projects that includes
short films, Educational Films and Advertisements. The Team is focused on continuous learning while
enjoying each creative project and developing good relations within the Film and Television Industry as we
believe that Film Production is a collaborative field and need value add from each department and every
possible expert in the field..

8. Problem Statement
• List down the critical factors affecting cost and efforts
• Create defined process for various stages of the film making
• Understand probable failure mode and define probable control plans
• Reduced cost for filmmaking
Redesign the filmmaking process for Marathi cinema applying lean and six sigma approach to reduce the cost and
efforts by 25% without affecting creative liberty and quality of the product
Benefits
Expected Outcome
• List of Critical factors affecting cost of the filmmaking
• Re-designed process
• FMEA (Failure Mode Effect Analysis) template
• Various checklists

9. Research Methodology - Approach
Lean : Lean is a systematic approach of eliminating waste so every step adds value for the Customer, In this
project we will use waste elimination technique of lean methodology which will affect
• Cost
• Quality
• Delivery
Six Sigma : Six sigma is process improvement methodology which helps to reduce variation , We will be using
various tools which gets used six sigma methodology for process improvement. We will be using DMAIC – Re-
design methodology
• Define
• Measure
• Analyze
• Improve
• Control

10. Process Flow Diagram
50 K Process map
Inputs (Xs) Outputs (Ys)
C/U/S
Script Film for distribution
Screenplay Cost incurred for the film
Locations
Shooting Resources
Creative Team
Finance
Film Making
Process
Film Making Process
5 K Process map
Inputs (Xs) Process Outputs (Ys)
C/U/S
Availability of saleable Idea, Story Story
Skill of the Writer Tentative Budget
Availability of Funds/Producer
Funds
Availability of budget components/template
Correctness of estimation
Film making Knowledge Screen play
Availability of Execution plan Shooting /Production plan (Elaborated)
Skill of Screenplay writer Identified Cast and Crew members
Skill of story boarding artist Identified distribution channel
correctness location hunting process Identified marketing strategy
availability of technological information identified locations
Skills of Director Accurate Budget estimation
Skill of Executive Producer
Availability of team
Skill/Eligibility of distributor
Quality of Camera
availability of cast and crew members Raw shooting footage
funds Review comments
skill of Assistant directors
Skill of director
efficiency of executive producer
availability of location and permissions
Film Making Process
Design
Pre-Production
Production
(Shooting)
Transfer to C&E Delete Input (x)
Inputs (Xs) Process Outputs (Ys)
C/U/S
Availability of saleable Idea, Story Story
Skill of the Writer Tentative Budget
Availability of Funds/Producer
Funds
Availability of budget components/template
Correctness of estimation
Film making Knowledge Screen play
Availability of Execution plan Shooting /Production plan (Elaborated)
Skill of Screenplay writer Identified Cast and Crew members
Skill of story boarding artist Identified distribution channel
correctness location hunting process Identified marketing strategy
availability of technological information identified locations
Skills of Director Accurate Budget estimation
Skill of Executive Producer
Availability of team
Skill/Eligibility of distributor
Quality of Camera
availability of cast and crew members Raw shooting footage
funds Review comments
skill of Assistant directors
Skill of director
efficiency of executive producer
availability of location and permissions
Film Making Process
Design
Pre-Production
Production
(Shooting)
Transfer to C&E Delete Input (x)

11. Cause and Effect Matrix
100
Rating of Importance to Customer
10 9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Process Step Process Inputs
Filmfor
distribution
Costincurred
forthefilm
Total
Design Skill of the Writer 9 9 171
Design Availability of Funds/Producer 9 9 171
Design Funds 9 9 171
Design Film making Knowledge 9 9 171
Design Availability of Execution plan 9 9 171
Pre-Production Skill of Screenplay writer 9 9 171
Pre-Porduction Skills of Director 9 9 171
Pre-Porduction Availability of team 9 9 171
Production (Shooting) funds 9 9 171
Production (Shooting) Skill of director 9 9 171
Production (Shooting) efficiency of executive producer 9 9 171
Design Availibility of saleable Idea,Story 9 3 117
Post-Production (First Print) Skill of editor 9 3 117
Pre-Porduction correctness location hunting process 3 9 111
Enter C&E Break Point:
Cause and Effect
Matrix
Sort & Move To FMEA
Sort C & E Matrix

12. Failure Mode Effect Analysis
C&E Break Point 220
Process or Product Name: Prepared by: Narendra Page of
Responsible: FMEA Date (Orig): #### (Rev):
Process Step Key Process Input Failure Modes - What
can go wrong?
EFFECTS
CORRRECTED
S
E
V
Causes O
C
C
Current
Process
Controls -
Detection
D
E
T
R
P
N
Actions Recommended
Design Availability of Execution
plan
unrealistic plan Efforts and Cost overrun 10 process not available 10 7 700 Have a checklist, what
should be included in Plan,
Establish review
mechanism, Have realistic
check
Pre-Production Skill of Screenplay writer Efforts and Cost overrun 9 Locations and shooting
cost not properly thought
upon
7 8 504 Have a checklist , waste
elimination mechanism
Production (Shooting) efficiency of executive
producer
Crew looses interest 8 Producer / director not
enquired about EP
8 7 448 Set a process of EP
enquiry , (call peviously
worked director, Check for
his history records)
Pre-Production Skill of Screenplay writer Financial Knowledge is
missing
Efforts and Cost overrun 9 Costly scenes 6 7 378 Arrange Financial
management sessions
Pre-Production Skills of Director Efforts and Cost overrun 9 Lack of film making
knowledge
5 7 315 Arrange film making
training sessions
Pre-Production Skills of Director Unskilled Director Not able to manage the
crew
7 Lack of experience 7 6 294 Arrange management
training sessions
Design Availability of Execution
plan
Incorrect plan Efforts and Cost overrun 10 Lack of knowledge 4 7 280 Have a checklist, what
should be included in Plan,
Establish review
mechanism, Have realistic
check
31-Aug-10
Film Making process
Narendra Singh
Process/Product
Failure Modes and Effects Analysis
(FMEA)Sort FMEA Print FMEAAdd Row

13. Overall Process
* Courtesy – CANAL+

14. Stakeholders Involved in process
Writer writes a script
Producer, Investor,
Film company buys the right
to make a move
Screenplay writer converts
idea/script into screen play
Director, Producer, Editor,
Art director,
Cinematographer ,
Production designer meet
and decide next action plan
Storyboard maker
illustrates the screen play in
pictures (detailed()
Other crew members like
costume designer, location
manager, dance director,
music director, assistant
directors get involved
Casting agency's help to
identify , manage auditions
and negotiate the cast for
the film
Proceeds for other logistics
like locations, hiring other
crew , equipment's etc.
Director oversees everything
and work with producer and
cinematographer turns
story board into series of
shots
Production design and
creative team work on look
and feel of cat and locations
Cinematographer takes
control of camera and light
related work and help the
planning
Make up artists , costume
designer, art directors work
together with artists and
director and design
accordingly
Actual shooting happens –
Executive Producer makes
sure everything is according
to plan
Editor gets raw footage and
along with cinematographer
and director he prepare
rough cut film
DI artists, VFX team work
for next processing
Music director gets locked
version of film for
background score
Sound engineers and editor
work to make final print of
the film
After post processing film
gets handed over for
marketing and distribution
Stakeholders
controlling cost
Writer
Screenplay writer
Executive Producer
Director
Cinematographer
Assistant Director

15. Critical factors affecting COST and EFFORT
• Skill of Screenplay writer
• Availability of Execution plan
• efficiency of executive producer
• Skills of Director
• Skill of Assistant directors
• Film making Knowledge before starting the film
• Use of digital techniques in film making
• Ability to identify the value added and not value added scenes
• Clarity about budget of the film to entire crew members
• Availability of checklist during pre-pod and post-production

16. Key process changes suggested
** Changes Marked with Shading

17. The Seven Forms of Waste needs to be
taken care while film making
• overproduction (shooting extra scenes which are not required )
• Waiting (periods of inactivity , e.g. waiting for makeup to be done)
• Transport (unnecessary movement of materials, location changes )
• Extra Processing (rework and reprocessing, errors while shooting , AD’s not
at work)
• Inventory (excess inventory not directly required for current orders, extra
lights , equipment which are not required on shooting day)
• Motion (extra steps taken by crew due to inefficient layout, wrong camera
positions)
• Defects (retakes due to avoidable mistakes, filed issues)

18. The Seven Forms of Waste
• Overproduction :
• Shooting extra scenes which are not required
• Waiting :
• people – makeup not done, artists not available on time, unnecessary breaks
• Information – script not provides to stakeholders, weather information not considered
• machinery – camera issues, battery problem, cable problem , display screen is not
working , camera heated during day shoot,
• Materials – lights not arrived, light setting taking time, study not done earlier
• Transportation :
• Unnecessary location changes
• Break fast, lunch , tea arranged away from location
• Artists demands pick-up – drop

19. The Seven Forms of Waste
• In appropriate processing:
• No separate assistant assigned for junior artists, public control, field clearance,
main artists practice
• Director is not managing the crew
• Sound related issues while shooting , no proper cue sheet maintained, no proper
claps given, Actors look into the camera immediately after scene ends (before
cut)
• Unnecessary Inventory:
• Excessive lights , camera accessories ordered
• Excessive storage equipment
• Inappropriate planning

20. The Seven Forms of Waste
• Motion :
• people or equipment moving or walking more than is required to perform the
shooting
• Location changes not planned properly (same location scenes to be shoot
sequentially )
• Facilities are not near to the shooting location
• Defects :
• Frequent errors in paper work,
• More retakes
• Retakes due to sound related issues
• Camera framing issues

21. Checklist for Producer
• Is idea/story saleable?
• Is decision analysis review done with story? (DAR attached in next
screen)
• Is my director is good at management?
• Is my screen play writer is experienced ?
• Is screen play writing checklist review done after screenplay?
• Is my executive producer (EP) is experienced?
• What are past producers/directors comments for my EP? (contact
them)
• Does my all key crew members aware about the budget?
• Are cost cutting measures followed while writing screen play?
• Is camera selection method followed?

22. Checklist for Screen play writer
• Is this scene adding any value to the story ?
• Can I write this scene without changing the location?
• Can I use visuals instead of dialogs ?
• How much time will it require to complete the shoot of the scene?
• What is the exact time of the scene (Day / Night and Time)
• Can I merge connecting scenes ?

23. Checklist for EP
• Is my production plan reviewed ?
• Am I taken care of half shift for the shoot day?
• What would be the wake-up call , is it realistic for the crew involved in
the scene?
• Am I contacted with weather department , analyzed day light timings ?
• Is legal advisor given clearance for location?
• Location permissions are ready ?
• Does any other events planned (e.g. any festival, marriage ) near the
location on shooting day?
• Is mock shoot done for the day (shoot across the table) ?
• Do I have required authorities to connect with crew members?
• Do I have all important contacts printed ?
• Have I checked all artists shooting patterns and planned accordingly ?

24. Findings/Comments
• Location changes and Camera selection are important factors which
affect the budget of the film
• Camera selection should be done by producer and director (Red, ARRY
Alexa, DSLR (Canon, Sony) , Black magic 4K)
• Camera should selected as per need of the script
• Screen play writer is key member in cost and effort cutting
• While taking creative liberty he should think to avoid location changes
• He should see how scene connects with each other without changing
locations
• Experience of executive producer is important
• Check EP’s history and train him if he is lacking in experience (Audition
of EP)
• Training sessions should be arrange for all key crew members before
the production starts , it may include entire film making awareness)

25. Findings/Comments
• Legal advisor must review the script and dialogs to avoid the issues at
the time of production
• Director must be aware of various artists associations and how to
handle the crew
• Director must take review of shooting every 2 hours on shooting day.
• Director should check if half shift is required , if yes then utilize the full
hours of half shift
• If schedule is completed early plan the next day and utilize the day for
reviewing entire footage
• There should not be multi-tasking at the time of shoot
• Each department should have their roles and responsibilities clear

26. Conclusion
• Even though film making is creative process we need to understand
the investors money is involved in it
• While taking creative liberty for best user experience “waste” can be
eliminated from the process
• By simply following certain review steps cost overrun can be controlled
• Director of the movie must be a good manager

27. Usage
Short film .. Dand The Penalty
Estimated Cost – Approx. 3.2 Lacs
Actual Cost – 2.5 Lacs (22% saving)
Cost Cutting Areas
• Location Selection
• Waste Elimination
• Use of new media (VFX)
• Maximum utilization of resources
• Using checklists for review

28. Is this scene adding any value to the story ? Checked 6 Scenes can be eliminated , saves 2 locations
Can I write this scene without changing the location? Checked - Garrage shot can be mearge if sequence chang
Can I use visuals instead of dialogs ? Checked - Car Inside scenes changed
How much time will it require to complete the shoot of the scene? Checked for all
What is the exact time of the scene (Day / Night and Time) Mentioed
Can I merge connecting scenes ? Checked - sequence changes done
This scene has
been eliminated
since not adding
much value to the
story , Saved
location cost,
efforts cost
Use of Screen Play check list
Screen Play Check list sample
VFX used for accident shot – saved vehicle damage cost

29. Conclusion
• Even though film making is creative process we need to understand
the investors money is involved in it
• While taking creative liberty for best user experience “waste” can be
eliminated from the process
• By simply following certain review steps cost overrun can be controlled
• Director of the movie must be a good manager

30. References
• Film making process – CANAL+
• Lean and Six Sigma Frame work
Thanks
• Devendra Shinde,Rajneesh Kalawant - Vedarth Creations
• Pravin Tarade – Club11

31. Thank You