From World Class Applications of Six Sigma: Real World Examples of Success
Jiju Antony Maneesh Kumar M. K. Tiwari

5.1 Introduction

This chapter deals with a case study performed in an automobile company to eliminate the defects in casting product using Six Sigma problem-solving methodology. The application of Six Sigma methodology (DMAIC) reduced the number of defects in the engine manufacturing process and thereby improving customer satisfaction and business profitability for the company. The five-step Six Sigma methodology (DMAIC) used for this case study is depicted in Figure 5.1.


Figure 5.1: The five-step methodology of Six Sigma.

The five-step process of the case study started with the define phase. The Define phase involved identifying a project's critical to quality (CTQs) characteristic driven by the voice of customer (VOC), followed by developing team charter, and finally defining a high level process map connecting the customer to the process and identifying the key inputs and requirements.

In the measurement phase, the team identified the key internal processes that influence CTQs and measures the defects currently generated relative to those processes. The project's CTQs were selected with the help of a fishbone diagram, Cause and Effect matrix, Pareto chart, etc. A Gauge R&R (repeat-ability and reproducibility) study was conducted to check whether the measurement system is acceptable or not.

The Analyze phase mainly consisted of three steps: establishing process capability with the help of capability indices, defining performance objectives by the team benchmarking, and identifying the sources of variation by performing an ANOVA test and hypothesis testing. Based on the above information,...

Copyright Dr. Jiju Antony, Dr. Ashok Kumar and Mr. Ricardo Bañuelas 2006 under license agreement with Books24x7

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Topics of Interest

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Overview Define means to establish the cause of a problem and to set the boundaries of the problem. The Define phase helps the team to picture the process over time and provides insight for the team...