MANAGEMENT CERTIFICATIONS

SHASHWAT GUPTA
Professor (WMT)
IRIMEE
CERTIFICATIONS IN INDIAN RAILWAYS
❏ Green Certification (CII) – Environmental performance

❏ ISO 14001 : 2015 – EMS/IMS certification

❏ ISO 50001 : 2018 – Energy Management System

❏ OHSAS 18001 : 2007 – Occupational Health & Safety

(now ISO 45001 : 2018)
❏ ISO 3834 : 2005 – Weld Quality Certification
GREEN CERTIFICATION (GREENCO)
 GREEN CERTIFICATION
❖ By Memorandum of Understanding (MoU) between Railways
and Confederation of Indian Industry (CII) in July 2016 to
facilitate Green initiatives on Railways
❖ Green certification assesses several environmental parameters
❖ Indian Green Building Council (IGBC) along with RB’s
Environment Directorate developed Green Rly Stations Rating

✓ 39 Workshops, 7 PUs, 8 Loco Sheds and one Stores depot, 19 Railway

stations and 27 other establishment buildings are Green certified
GREEN CERTIFICATION
❏ Energy Efficiency (EE)
❏ Renewable Energy (RE)
❏ Greenhouse Gas (GHG)
❏ Water Conservation (WC)
❏ Waste Management (WM)
❏ Material Conservation,
Recycling & Recyclability (MC)
❏ Green Supply Chain (GSC)
❏ Others (OS)
GREEN CERTIFICATION
 GREEN BUILDINGS & RAILWAY STATIONS
❖ Green buildings reduce or eliminate negative environmental
impacts while also creating a positive impact
❖ Green buildings promote healthier & more eco-friendly working
❖ Green building rating, training and certification is provided by
the Indian Green Building Council (IGBC), under the CII

✓ Many Railway buildings are IGBC certified, e.g. Rail Nirman Nilayam
Hyderabad - 1st, & ICF GM office, RWF Administrative Building,
DMW Administrative Building (all Platinum)
 GREEN RAILWAY STATIONS
❖ CII-IGBC with the support of Environment Directorate of Railway
Board has developed the Green Railway Stations rating
❖ Voluntary, consensus-based programme to address environmental
sustainability of Indian railway stations, reducing adverse
environmental impacts, enhancing the commuter experience
and providing manifold gains in reduced costs and increased
efficiency

✓ Notable green stations are Jaipur, Visakhapatnam, New Delhi and

Asansol (Platinum), CSMT (Gold), and Kevadiya-1st
ADVANTAGES OF GREEN CERTIFICATION
❖ Environment-friendliness

❖ Cost reduction

❖ Energy saving

❖ Technical assistance and training for new technologies,

techniques & processes

❖ Drives innovation

❖ Image building
ISO 14001 : 2015
 ISO 14001 : 2015
❖ ISO 14001 is an internationally recognized voluntary standard
for an Environmental Management System (EMS) to holistically
improve environmental performance, governed by ISO/TC 207
❖ It can be integrated with other ISO standards for greater
efficiency and cost-savings, plus environmental sustainability,
❖ The newest version (2015) requires greater involvement of
organizational leadership and tighter integration of
environmental aims with the organization’s strategic goals
✓ All PUs, major Workshops, Diesel Sheds, Coaching & Freight Depots,
MEMU/DEMU Sheds, railway stations (e.g. Secunderabad Jn., SCR)
EMS FRAMEWORK
TC/207 SC1
IMPLEMENTING ISO 14001: ANALYSIS & DOCUMENTATION
ISO 14001 BENEFITS
❖ A step ahead of existing statutory and regulatory requirements
❖ Certification process is an employee-driven workflow, so enhances
collaborative engagement and leadership among the staff
❖ Achieve strategic business aims by incorporating environmental
issues into business management
❖ Provides a competitive financial advantage by improved efficiency,
reduced costs, higher stakeholder confidence and a better image
❖ Encourage better environmental performance of suppliers
ISO 50001 : 2018
 ISO 50001 : 2018
❖ ISO 50001 is an international standard for Energy Management
System (EnMS) to systematically improve energy performance,
including usage, efficiency, security & conservation, and
❖ Requires demonstration of continual energy performance
improvement (ISO/TC 301)
❖ Features a data-driven approach to energy management (rather than
the multipronged qualitative approach of ISO 14001)

✓ Starting with ICF Chennai in August 2015, all 8 Production Units and
44 major Workshops are ISO 50001 certified
ISO 50001 : 2018 IMPLEMENTATION
Like other ISOs, 50001 works on the Plan-Do-Check-Act (PDCA)
model and provides a set of requirements for organizations to:
❏ Develop a policy for more efficient energy use patterns,
❏ Fix targets and objectives to meet that policy,
❏ Gather data to better understand and make decisions
concerning energy use,
❏ Measure the results obtained,
❏ Review the effectiveness of the policy,
❏ Continually improve energy management
ISO 50001 : 2018 IMPLEMENTATION
ISO 50001 BENEFITS
Improved energy performance, implemented in a standardized and
scalable manner, carries many benefits for the organization, including:
❖ Lower costs,

❖ Better usage stats,

❖ Reduced environmental impact,

❖ Enhanced staff morale and

❖ Better public image

 ISO 45001 : 2018
(formerly OHSAS 18001 : 2007)
 ISO 45001 : 2018
❖ ISO 45001 is an ISO standard that specifies (ISO/TC 283)
requirements for an Occupational Health & Safety (OH&S)
management system to enable organizations to provide safe and
healthy workplaces, prevent work-related injury and ill health, and
❖ Requires organizations to proactively improve OH&S performance,
❖ Based on OHSAS 18001, ILO-OSH guidelines, ILO international
labour standards, various other national standards

✓ Major Railway units like PUs, Workshops, CTIs, etc are certified.
ISO 45001 : 2018 – SALIENT FEATURES
✓ Focus on mental health of employees
✓ Focus on the need for a management system rather than the
management of any individual set of occupational hazards,
✓ Focus on involvement of top-level leadership and collaborative
employee participation
✓ Does NOT address issues such as product safety, property
damage or environmental impacts
✓ Similar structure to ISO 14001, with documented policies,
targets, compliance protocols, and focus on improvement
ISO 45001 : FOCUS
✓ Employee mental health (45003)
✓ Need for a management system,
not of any individual hazard,
✓ Involvement of top-level
leadership and collaborative
employee participation
✓ Does NOT address issues like
product safety, environmental
impact or
IMPLEMENTING ISO 45001 : 2018
ISO 45001 BENEFITS
❖ Adherence to all major national and international legal

requirements for employee health and safety,

❖ Increased efficiency by integration with other ISO systems,

❖ Improved employee morale with collaborative leadership,

❖ Better public image, enabling international engagement

❖ Ripple effect to subcontractors and vendors in the chain

 IRIS 45001 : 2018
(or ISO/TS 22163 : 2017 +)
 IRIS or ISO 22163 : 2017 CERTIFICATION
❖ IRIS = International Railway Industry Standard, that is
❖ Managed by UNIFE = Association of European Rail Industry
❖ Aims to increase quality and efficiency in the rail sector through a
universal evaluation system of assessment guidelines and audits,
❖ Largely based on ISO 9001 : 2015 plus Railway-specific requirements,
❖ General quality guidelines of ISO 9001 applied to Railway products
and services to meet standards and enhance customer satisfaction
 Objective

IRIS IN INDIA Transparent

Impact on BMS:
❏ Project- , Change- &
❏ Configuration Mgt
❏ Obsolescence Mgt,
❏ RAMS (Rel., Availab.,
Maint., Safety),
❏ LCC (Life Cycle Cost)
❏ First Article Inspn
IRIS IN INDIA
❖ Currently 2172 active IRIS
licenses worldwide,
❖ Several are in India also →
❖ Major Railway PUs are IRIS
certified: RCF/KXH,
MCF/RBL, ICF/MAS,
BLW/BSB
❖ Major suppliers like NEC,
IRIS CERTIFICATION BENEFITS
SYSTEM INTEGRATORS EQUIPMENT OPERATORS
MANUFACTURERS
❏ Improve quality among ❏ Enter and update data on ❏ Mandatory requirement
various production sites the IRIS platform for participation in the
❏ Simplify the process of ❏ Information of successful European rail industry
❏ Gain improvements
evaluating and approving certification can be made
across the entire supply
suppliers available to all systems chain, enhancing both
❏ Remove the need for integrators and railway equipment and
own-approval audits prospective clients rolling stock systems
❏ Have access to accurate ❏ Attain higher visibility in ❏ Useful image- and
and reliable data from the industry brand-building
one common IRIS web ❏ Save time and money by ❏ Regular audits mean that
the organization mgt
database increasing efficiency
system remains updated
5S SYSTEM & CERTIFICATION
(NPCI / QCFI / JUSE)
5S CONCEPT & WORKING PRINCIPLES
❖ Japanese workplace
organization method to
maximimize productivity &
efficiency,
❖ Sometimes regarded as part
of 6σ or 6s system,
❖ “A place for everything and
everything in its place”
5S : SORT

Sort and discard unnecessary items in the workplace, arrange the rest
 5S : STRAIGHTEN

Set in order to allow necessary items to be picked easily without waste of time
5S : SHINE

Shine up and clean the workplace completely leaving no dust or dirt at all
5S : STANDARDIZE

Standardize housekeeping & workplace organization systems to high level

 5S : SUSTAIN

Sustain this system by inculcating behavioural change through regular training

5S CERTIFICATION IN INDIA: PROCEDURE
REGISTRATION:
PRE-AUDIT:
CERTIFICATION AUDIT: CERTIFICATION:
Organization can
Industrial visit by
register to become The certifying body Based on the score
the certification
part of the NPC or brings its team for a obtained, a certificate is
body/team for
QCFI for this step-by-step check of awarded at one of 5 levels,
preliminary survey
purpose of training adherence to 5S rules validity usually 3 yr
and handholding
and certification

RECERTIFICATION: SURVEILLANCE AUDIT:

After certificate validity, the During certificate

organization can reapply for validity, the certifying
certification and update body carries out an
certification scope based on annual surveillance audit
their requirement for score update/upgrade
5S SYSTEM AND CERTIFICATION BENEFITS
EMPLOYEES MACHINES & MATERIALS & WIP PRODUCTS &
TOOLS CUSTOMERS

❏ Disciplined, ❏ Early problem ❏ Smoother flow ❏ Clean

more aware, identification & of materials and workspace
motivated to diagnosis WIP ensure dust-free
❏ Organized Floor final product
improve ❏ More accurate
space ❏ High product
❏ Better team with longer ❏ Inventory of quality
spirit and lifespan & less materials and ❏ Greatly
co-operation breakdown due WIP become enhanced
❏ Discipline to to daily cleaning clearly visible image for
follow safer and and regular ❏ Reduced marketing
better work calibration and material ❏ Higher rates of
handling time innovation
styles servicing
and cost
6σ METHODOLOGY & CERTIFICATION
WHAT IS SIX-SIGMA METHODOLOGY?
❖ Six Sigma is a methodology that utilizes statistical tools and concepts to
identify variations or defects in a process.
❖ Using measurement to reduce defects to virtually zero for every
products, process and transaction, for the purpose of achieving Total
Customer Satisfaction and enhancing shareholder value.
❖ Disciplined, quantitative approach for improvement of defined metrics in
all aspects of the business,
❖ Drives the overall process of selecting the right projects based on their
potential in improving performance metrics
❖ Selecting and training the right people to get good business results
TOOLS OF SIX-SIGMA METHODOLOGY
❖ COMPUTERISED DATA ACQUISITION

❖ PROCESS CONTROL CHARTING

❖ PARETO ANALYSIS

❖ ROOT CAUSE ANALYSIS

❖ FISH BONE DIAGRAM

❖ PERIODICAL EXECUTIVE REVIEWS

SIX SIGMA SALIENT FEATURES
❖ Process Measurement Methodology
❖ Helps improve the bottom line
❖ Customer Satisfaction Improvement Process,
❖ Specific methods to ensure near-zero defect operation,
❖ New definition in Quality = Near-Zero Defect
❖ 6-Sigma = 3.41 defects/Million Operations.
❖ 6-Sigma is about profit improvement
UNDERSTANDING 6σ
6σ PARADIGM: WHAT’S NEW ABOUT IT?
FROM TO

➢ Manufacture view of ➢ Quality in all functions.

Quality ➢ Quality as No.1 objective
➢ Processes first for
➢ Quality as an objective consistent results
➢ Results first ➢ Quality as a new way of
➢ Quality as conformance doing things
➢ Customer-driven Quality
➢ Internal quality push
efforts.
➢ Ignore cost of poor quality ➢ Constantly communicate
➢ Judgement-based quality Cost of Poor Quality.
decisions ➢ Decisions based on facts.
6σ: INVOLVEMENT OF TOP MANAGEMENT
❖ The Six Sigma journey is led from the top

❖ Top Management drive Six Sigma through their business

❖ Quality is No.1 objective for all employees

❖ All Management reviews begin with a review on Quality

❖ Organization leadership must engage with client on a

near-daily basis for quality assessment & improvement

SAMPLE 6σ PROJECT SEQUENCE
❖ Leadership Jumpstart Event (2 days) White Belt
❖ Decision on Six Sigma Project teams
Yellow Belt
❖ Planning and baseline analysis
❖ Six Sigma Champions Training (4 days) Green Belt
❖ Black Belt Training (Action Learning and Mentoring)
➢ 5 Segments of training spread over 5 months Black Belt

❖ Projects completed and Financial Benefits Validated

Master Black
❖ Black Belts Certified after 2 Months’ Sustained rise Belt
6σ METHODOLOGIES: DMAIC vs DMADV

DMADV

DMAIC
99% GOOD RESULTS IN...
❖ At least 11,000,000 wrong drug prescriptions each year.
❖ More than 110,000 new born babies accidentally dropped by
Doctors and nurses each year
❖ No electricity for 54 hours each year
❖ No television transmission for nearly 1:04 hours per week
❖ Four short or long landings per day
❖ 16 Railway accidents per day
❖ 16 minutes per week of unsafe water supply per day
…. SO 99% IS NOT GOOD ENOUGH
WHAT DIFFERENCE DOES IT MAKE?
3σ 6σ

➢ At least 54,000 wrong ➢ One wrong drug

drug prescriptions a year prescription in 25 years
➢ Unsafe drinking water for ➢ Unsafe drinking water for
about 2 hours per month one second per 16 years
➢ Five short or long landings ➢ One short or long landing
at O’Hare International at all the airports in the
Airport every day U.S in 10 years
OTHER POSSIBLE CERTIFICATIONS
OTHER QUALITY CERTIFICATIONS
❖ ISO 3834 : 2005 certification for weld quality

➢ ISO 3834-1 to -4 (ISO/TC 44/SC 10) for quality management

in the field of welding, is a key certification including the usual
ISO quality assessment standards and documentation, plus a
team effort from the top for ground-level improvement
(Welding Manager)
➢ Aspires to the EN15085 standard for welding of Railway
vehicles
❖ ISO 26000 guidance on social responsibility (free, no charge)
CONCLUSION: CERTIFICATION BENEFITS
❖ Standard indicator of an organization’s competitiveness and
environmental sustainability
❖ Indian Railways is a key part of India’s transport sector, and so
must play a key role in promoting sustainable mobility
❖ To this end, there is a need for policy framework to stimulate modal
shift. Various process improvements are also required
❖ These certifications are a good way for the Railways to assess and
upgrade itself on an internationally recognized metric