A PROJECT REPORT ONAPPLYING LEAN AND SIX SIGMA APPROACH FOR FILM MAKING PROCESS TO REDUCE EFFORTS AND COST

Submitted By: Sachin PanditMBA – Media & Entertainment IVth Semester – Oct 2015Register Number: 14297603BHARATHIDASAN UNIVERSITY

Table of Contents• Declaration

• Certificate from company

• Background and objective

• Company profile

• Problem statement

• Project benefits and expected outcome

• Research methodology

• Process flow diagram

Table of Contents…cont..• Stakeholder matrix

• Cause and Effect matrix

• Failure mode effect analysis

• Critical inputs

• Conclusion and redesigned process

• Usage

• References

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

Certificate

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

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..

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

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 • DeliverySix 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

Process Flow Diagram

50 K Process map

Inputs (Xs) Outputs (Ys)C/U/S

Script Film for distributionScreenplay Cost incurred for the filmLocationsShooting ResourcesCreative 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 StorySkill of the Writer Tentative BudgetAvailability of Funds/ProducerFundsAvailability of budget components/templateCorrectness of estimation

Film making Knowledge Screen playAvailability of Execution plan Shooting /Production plan (Elaborated)Skill of Screenplay writer Identified Cast and Crew membersSkill of story boarding artist Identified distribution channelcorrectness location hunting process Identified marketing strategy availability of technological information identified locationsSkills of Director Accurate Budget estimationSkill of Executive ProducerAvailability of teamSkill/Eligibility of distributor

Quality of Cameraavailability of cast and crew members Raw shooting footagefunds Review commentsskill of Assistant directorsSkill of directorefficiency of executive produceravailability 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 StorySkill of the Writer Tentative BudgetAvailability of Funds/ProducerFundsAvailability of budget components/templateCorrectness of estimation

Film making Knowledge Screen playAvailability of Execution plan Shooting /Production plan (Elaborated)Skill of Screenplay writer Identified Cast and Crew membersSkill of story boarding artist Identified distribution channelcorrectness location hunting process Identified marketing strategy availability of technological information identified locationsSkills of Director Accurate Budget estimationSkill of Executive ProducerAvailability of teamSkill/Eligibility of distributor

Quality of Cameraavailability of cast and crew members Raw shooting footagefunds Review commentsskill of Assistant directorsSkill of directorefficiency of executive produceravailability of location and permissions

Film Making Process

Design

Pre-Production

Production (Shooting)

Transfer to C&E Delete Input (x)

Cause and Effect Matrix

100

Rating of Importance to Customer10 9

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Process Step Process Inputs Film

for

dist

ribut

ion

Cos

t inc

urre

d fo

r the

film

Total

Design Skill of the Writer 9 9 171Design Availability of Funds/Producer 9 9 171Design Funds 9 9 171Design Film making Knowledge 9 9 171Design Availability of Execution plan 9 9 171Pre-Production Skill of Screenplay writer 9 9 171Pre-Porduction Skills of Director 9 9 171Pre-Porduction Availability of team 9 9 171Production (Shooting) funds 9 9 171Production (Shooting) Skill of director 9 9 171Production (Shooting) efficiency of executive producer 9 9 171Design Availibility of saleable Idea,Story 9 3 117Post-Production (First Print) Skill of editor 9 3 117Pre-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

Failure Mode Effect AnalysisC&E Break Point 220

Process or Product Name: Prepared by: Narendra Page ofResponsible: FMEA Date (Orig): #### (Rev):

Process Step Key Process Input Failure Modes - What can go wrong?

EFFECTS CORRRECTED

SEV

Causes OCC

Current Process

Controls - Detection

DET

RPN

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-10Film Making process

Narendra Singh

Process/Product Failure Modes and Effects Analysis

(FMEA)Sort FMEA Print FMEAAdd Row

Overall Process

* Courtesy – CANAL+

Stakeholders Involved in process

Writer writes a scriptProducer, 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

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

Key process changes suggested** Changes Marked with Shading

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)

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

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

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

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?

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 ?

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 ?

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)

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

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

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

Is this scene adding any value to the story ? Checked 6 Scenes can be eliminated , saves 2 locationsCan I write this scene without changing the location? Checked - Garrage shot can be mearge if sequence changCan I use visuals instead of dialogs ? Checked - Car Inside scenes changedHow much time will it require to complete the shoot of the scene? Checked for allWhat is the exact time of the scene (Day / Night and Time) MentioedCan 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

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

References

• Film making process – CANAL+• Lean and Six Sigma Frame work

Thanks • Devendra Shinde,Rajneesh Kalawant - Vedarth Creations• Pravin Tarade – Club11

Thank You