Application of Six Sigma Methodology in an Automotive Manufacturing Company: A Case Study

Continuous improvement is the prime requirement for all industries to sustain and grow in the competitive global market. This paper is a case study of a manufacturing industry in Taiwan, facing the problem of rejection in the brushless motor product. The DMAIC (Define, Measure, Analyze, Improve, and Control) cycle was used to improve processes to reduce the rejection rate. In the Define phase, anything related to processes, products, suppliers, customers, and customer needs related to good quality products were determined. SIPOC diagrams (Supplier, Input, Process, Output, and Customer) and Critical to Quality (CTQ) were identified. The Measure phase focused on data collection by determining the baseline of the process and determining the root causes of the process. DPMO and the Control Chart were applied in this phase. In the Analyze phase, the causes of production process failures that result in defective products were identified. Tools like Pareto Diagram, Fishbone Diagram, and FMEA were used in this phase. In the Improve phase, the improvement solutions in overcoming priority problems were determined by using the 5W + 1H tool. Several improvement solutions were implemented, such as improvement in inspection methods, re-selection for the supplier, increasing the number of workers, providing training to workers, and others. In the control phase, the Six Sigma values were improved. In January-May 2022, the Six Sigma level increased from 5.11 to 5.44.

Automated summary

Continuous improvement is essential for industries to thrive in the competitive global market. This case study focuses on a manufacturing industry in Taiwan that faced rejection issues with their brushless motor product. By employing the DMAIC cycle, the industry was able to identify and address the root causes of rejection, leading to a decrease in rejection rate. Various tools, such as SIPOC diagrams, Critical to Quality analysis, Pareto diagrams, Fishbone diagrams, and FMEA, were utilized to improve processes and achieve better quality products. The implementation of improvement solutions, including inspection method enhancements and supplier optimization, resulted in an improved Six Sigma level.