1. The document outlines a training calendar for a Green Belt project aimed at reducing material costs for a customer by minimizing import costs while preventing stock outs. 2. Key tools to be used include SIPOC, fishbone diagram, Pareto chart, histogram, control charts, FMEA, and P-MAP to analyze costs, identify critical variables, locate areas for improvement, and form a control plan. 3. Participants will apply concepts from the interactive training sessions to an actual project from their organization, with the goal of saving $82k in material costs over one year.

1. Training Calender
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Green Belt Project — Synopsis
REDUCE MATERIAL COST
Problem Statement: Customer push for lower Selling price.
LINKS Reduction in selling price would reduce margin. To maintain same
LSS Overview
2. Voice of Customer margin only way is to reduce the Raw material cost. Material is
[VOC]
3. Introduction to Variation Imported from Hong. Therefore, the challenge is to minimize Import
4. Rolled Throughput Yield
[RTY] Cost but prevent any Stock out Situation.
5. Minitab-Introduction
6. Thought Process Map
[TMAP] DEFINE Probability Plot was plot- transit material track-
7. SIPOC
8. Value Stream Mapping Used T-MAP tool in team ted to find out if data fol- ing was implemented
[VSM] selection, defining metrics, lows normal distribution. 3. Inventory Planning and
9. SPEED-Little's Law
Numerical Evaluation of objective, scope, and target Data points were almost Analysis not proper.
Metrics [NEM] savings touching the straight line Action: Implement
B. Measuring System
Evaluation [MSE] SIPOC Tool was used to and p-value was 0.914 MRP module
C. Failure Mode Effect
Analysis [FMEA]
analyze Input and Output which strongly indicates Control Charts
D. Seven Basic Tools Gaps that data is normally dis- Control Chart for Inventory
E. Design of Experiment
[DOE] H-PMAP tributed. Turns was monitored as
F. CONTROL From High level Process Detail P-MAP for Costing this was a Secondary Met-
map KPIV and KPOV and Material Procurement rics which should not get
were identified. was made adversely affected due to
Fish Bone Diagram was FMEA improvement in Primary
Contact:
prepared from these KPIV, Failure Mode Effect Metric.
KPOV. Critical Input vari- Analysis was conducted for MSE
Anupam Rohatgi
Phone: 9810156652
ables were identified. Material Procurement Measurement System
rohatgi.anupam@gmail.com
Pareto Chart was used to process. Following im- Evaluation was carried out
find out which items have provement areas were iden- for Quality control as this
high cost and volume and tified. was necessary for localiza-
would give most savings. 1. Inventory Closing Bal- tion of raw material
Also to understand which ance and Order Back- Control Plan
Lean Six Sigma:
are the items having most log was incorrect. Ac- Control Plan was formu-
Re-engineered of stock out situations, tion Plan: Train In- lated to sustain the im-
therefore required Air ventory controller and provement.
Shipments. put adequate controls Project Savings
HISTOGRAM 2. In-Transit material and US$ 82K were saved in 1-
Of Cost/Sales was plotted expected date of arrival year = INR 41 Lakh
to find out Mean, Std. Dev. EDA was not known.
Action: On-line in-

2. P AGE 2
About LSS GB Program
About LSS GB Program
Lean Six Sigma Green Belts are must for any or- Certification is given on successful completion
ganization of excellence in today’s competitive of Training Program.
world. Green Belts trained by us are well
equipped with GB Tools to find solution for com-
plex problems in a structured way using DMAIC We also conduct GB Training through e-
methodology. Learning or Correspondence.
Training Approach Individual coaching / Training is also provided.
Participants are grouped into teams. Presentations
on GB Modules are given by expert Trainers. The
entire session is interactive. Participants are en-
couraged to select an actual GB Project for their
organization. The concepts which they learn are
applied on the selected project . Role Playing,
Simulation Games, Minitab Exercises are con-
ducted , Assessment is done for each Module.
Study Material, Templates are provided to candi-
dates.
Duration & Certification
Ideally training is conducted in two sessions of 3-
days each so that participants go back to their
organization and collect the live data for their
selected project and then return for the second
session and apply the required Tools on their
selected project so their learning is permanent
and immediately beneficial to the organization.
Participants are given individual guidance and men-
toring for their project.Training is conducted at
Delhi/NCR, Jaipur , Chandigarh or
at Customer’s venue.