An application of Six Sigma methodology to reduce the engine-overheating problem in an automotive company

J. Antony, M. Kumar, M. K. Tiwari

    Research output: Contribution to journalArticlepeer-review

    60 Scopus citations

    Abstract

    Six Sigma is a systematic methodology for continuous process quality improvement and for achieving operational excellence. The overstatement that often accompanies the presentation and adoption of Six Sigma in industry can lead to unrealistic expectations as to what Six Sigma is truly capable of achieving. This paper deals with the application of Six Sigma based methodology in eliminating an engine-overheating problem in an automotive company. The DMAIC (define-measure-analyse-improve-control) approach has been followed here to solve an underlying problem of reducing process variation and the associated high defect rate. This paper explores how a foundry can use a systematic and disciplined approach to move towards the goal of Six Sigma quality level. The application of the Six Sigma methodology resulted in a reduction in the jamming problem encountered in the cylinder head and increased the process capability from 0.49 to 1.28. The application of DMAIC has had a significant financial impact (saving over SUS110000 per annum.) on the bottom-line of the company.

    Original languageBritish English
    Pages (from-to)633-646
    Number of pages14
    JournalProceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
    Volume219
    Issue number8
    DOIs
    StatePublished - Aug 2005

    Keywords

    • Automotive industry
    • Case study
    • DMAIC
    • Six Sigma
    • Tools and techniques

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