TCIL initiated its
Six-Sigma journey in September 2002, under the guidance
of consultant M/s ECS Limited. This initiative was primarily
launched for the reduction in process variability, to improve
the Quality yield and increase uptime at ETP. As such, during
the initial phase, three pilot projects were selected based
on organizational and customer needs:
| •
|
Reduction in Off
Gauge |
| •
|
Reduction in Luider
Band and Edge Pincher |
| •
|
Enhancement of
ETP uptime |
Cross-functional
teams working under the guidance of ECS achieved tremendous
success in reducing off gauge and increasing the uptime,
which led to the improvement in quality yield and productivity.
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During
the second phase, TCIL had tied up
with M/s Tata Motors Limited and under their guidance
following projects were taken up. Off gauge still
being the major defect, though reduced substantially
during the first phase was again taken up to achieve
further improvement. Power being one of the strategic
cost drives was also selected in this phase besides
quality yield improvement projects. |
| •
|
Reduction in Off
Gauge |
| •
|
Process Defects
at ETP |
| •
|
Reduction in Power
consumption at CRM & ETP |
| •
|
Transit Damage
and Rust |
 |
The above projects
have culminated into drastic improvements in Quality yield
(5%in last 5 years) and reduction in power consumption at
CRM &ETP (11%in last five years). All the projects were
carried out as per the DMAIC (Define, Measure, Analyse,
Improve, Control) methodology. During the above phases the
team members were exposed to numerous statistical tools
like,7 QC Tools, FMEA (Failure Mode Effect Analysis), Test
of Hypothesis, ANOVA (Analysis of Variance), DOE (Design
of Experiments)etc. On successful completion of projects,
which comprised exposure and test on above tools, 30 persons
were certified as Green Belts, by M/s Tata Motors Limited.
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