Improvement in quality performance by minimization of production defects at automobile manufacturing industry - A case study approach

Abstract

Six sigma is a specialized, stats-based, quantitative data-directed outlook and continuous improvement approach for reducing defects in a product, process or service. The proposed work was carried out at one of the most reputed automobile industries in Karnataka, India. The 6σ methodology was implemented in a highly authentic and crucial process in the manufacturing of automobiles. Define, measure, analyze, improve and control (DMAIC) phases of six sigma methodology are successful in the reduction of tolerance related problems in STA part of rear suspension and defectives rates were reduced from 27% to 7%. Data collection on all possible causes was carried out and data was analyzed and validated with the help of cause validation plan, regression analysis, and hypothesis testing. The present work carried out to Implement six sigma methodologies to quality problems will have a major impact on the revenues of the automobile industries. The proposed work will approximately, saves Rs 40,000 per annum. This proposed work will also guide and empower the knowledge of six sigma to all employees in the organization.