Journal
QUALITY AND RELIABILITY ENGINEERING INTERNATIONAL
Volume 27, Issue 8, Pages 1221-1234Publisher
WILEY
DOI: 10.1002/qre.1212
Keywords
Six Sigma; Kappa statistic; process capability evaluation; chi-square test; ANOVA; Taguchi methods
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Six Sigma is a data-driven leadership approach using specific tools and methodologies that lead to fact-based decision making. This paper deals with the application of the Six Sigma methodology in reducing defects in a fine grinding process of an automotive company in India. The DMAIC (Define-Measure-Analyse-Improve-Control) approach has been followed here to solve the underlying problem of reducing process variation and improving the process yield. This paper explores how a manufacturing process can use a systematic methodology to move towards world-class quality level. The application of the Six Sigma methodology resulted in reduction of defects in the fine grinding process from 16.6 to 1.19%. The DMAIC methodology has had a significant financial impact on the profitability of the company in terms of reduction in scrap cost, man-hour saving on rework and increased output. A saving of approximately US$2.4 million per annum was reported from this project. Copyright (C) 2011 John Wiley & Sons, Ltd.
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