Continuous improvement is one of the element of Lean manufacturing, Total Quality Management (TQM) and Total Productive Maintenance (TPM)

Seven Steps Business transformation helps in deployment of continuous improvement culture in organisations through their flagship training programmes conducted through Seven Steps Academy of Excellence.

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years, if they do not eliminate their job and move on with a new job profile or new field, the person is bound to be outdated.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 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 Systems and Six Sigma. It also provides Industry specific and approved training programmes for Engineering, Automotive, Retail, Aerospace, Healthcare, Hospitality, IT and Process Industries.

In the rising complexities of globalized business, if you are struggling to improve business operations and seeking a long haul business success, your business has left out with no option other than to optimize the business performance through analytical problem-solving approach and also to adopt proven breakthrough methodologies that multiply your ROI.

Are you in a struggle to optimize your business processes, cost and delivery? If so, it’s now high time for your business to adopt the most effective organization process improvement methodologies to meet your business goals and increase profits within this highly competitive business market.

If you are wondering what’s next?

Here’s your business game changer!

Can Lean and Six Sigma be an invaluable resource to achieve your business goals and improve the bottom line?

The answer is, Of course, “Yes”. But how? Let’s see here!

Lean and Six Sigma do both have similarities and differences. There are debates also as to which is better when it comes to applications in real-world scenarios for business process improvements. To understand this better, we can relate this specific to a context.

Lean Thinking and Six Sigma essentially have the same primary goal from a business perspective. Only focus, steps of implementation and approach is different.

Lean Thinking Approach

Lean is a methodology similar to Six Sigma used by organizations to optimize their business processes. It emphasized the need for zero waste ideal and for delivering value to the customers.

Traditional organizations are rated to be having more than 95% of waste in the processes as per Lean terminology. Less than 5% of Value-adding activities are seen. Value Stream mapping is one of the key tools used to identify waste activities and value-adding activities.

More importantly, lean focuses on achieving the results through Total Employee involvement right from top management to Housekeeping staff. Lean is also called Toyota Production System or TPS.

For achieving superior results, tools such as Hoshin Kanri or Policy Deployment, Kaizen, 5S with Visual Management, Quick Change-over or SMED, Load levelling or Heijunka are deployed for effective execution.

Company’s standing – and your own – in the business world

In this process, Lean methodologies are applied initially with proven similar tools such as Total Productive Maintenance and Theory of Constraints. Upon ensuring stability and good performance, Six Sigma concepts are parallel introduced to the processes for enhanced business results.

Seven Steps Academy helps in providing both In-house and public training programs in the field of Lean Six Sigma, Lean manufacturing, Lean Hospitals, Lean Construction, Lean Services, Lean Hospitality. Hands on support through onsite deployment of these methodologies is done through another vertical of Seven Steps Global Group.. Seven Steps Business Transformation Systems. From decades of experience in deploying Lean and Six Sigma in various industry segments, Seven Steps Business Transformation System recommends the usage of a combined methodology such as Lean Six Sigma.

Many professionals focus on core technical jobs at the entry-level jobs. As they progress in the ladder of professional development, knowledge of advanced tools such as Lean Six Sigma helps them to be more effective to perform the jobs and to lead their teams.

Wherever materials/items are stored & consumed, many times we either face stock out situation or excess inventory. Stock out situation can lead to huge production loss and excess inventory may leads to items becoming obsolete which leads to increase in cost. This situation may happen at house, factory, hospital, restaurant, automobile spare parts warehouse etc. To prevent stockout situation and maintain optimum inventory, “Kanban”, a powerful Lean tool is used. Stockout situation happens because we order the items late or order less quantity and excess inventory situation occurs many times due to excess ordering. Kanban is a Japanese word “signal for ordering”, where the system visually indicates when the item to be ordered and how much to be ordered.

Kanban tool is used in Manufacturing, Retailing, Warehouses, Restaurants, Construction and other areas where materials are stored and consumed. Kanban tool is also used in software industries and other office situations to optimise load and monitor different projects to complete as per schedule. Implemented effectively, Kanban will help in meeting “On Time Delivery” and “Improve Inventory Turns” which are two key Management Performance Indicators. For less number of items (less than 300nos) Visual system of triggering can be implemented with use of Kanban cards. When number of items are more than 300, ERP system can be used for implementing Kanban system with customized configuration.

ABC and Runner/Repeater/Stranger analysis for all the items is done to decide for which items Kanban to be implemented.

Seven Steps academy provides training in Lean manufacturing, lean services, Lean Hospitals where application of Kanban has yielded substantial improvement in productivity. For more information and for further training needs on 5S trainings, Lean Six Sigma, Six Sigma Green Belt, Six Sigma Blackbelt, Kaizen, QCO, SMED, Heijunka trainings, visit www.7stepsacademy.com