Case study in Six Sigma methodology: Manufacturing quality improvement and guidance for managers

Jiju Antony, E. V. Gijo, S. J. Childe

    Research output: Contribution to journalArticlepeer-review

    81 Scopus citations

    Abstract

    This article discusses the successful implementation of Six Sigma methodology in a high precision and critical process in the manufacture of automotive products. The Six Sigma define-measure-analyse-improve-control approach resulted in a reduction of tolerance-related problems and improved the first pass yield from 85% to 99.4%. Data were collected on all possible causes and regression analysis, hypothesis testing, Taguchi methods, classification and regression tree, etc. were used to analyse the data and draw conclusions. Implementation of Six Sigma methodology had a significant financial impact on the profitability of the company. An approximate saving of US$70,000 per annum was reported, which is in addition to the customer-facing benefits of improved quality on returns and sales. The project also had the benefit of allowing the company to learn useful messages that will guide future Six Sigma activities.

    Original languageBritish English
    Pages (from-to)624-640
    Number of pages17
    JournalProduction Planning and Control
    Volume23
    Issue number8
    DOIs
    StatePublished - 8 Jan 2012

    Keywords

    • cause validation plan
    • classification and regression tree
    • DMAIC
    • matrix plot
    • process capability evaluation
    • regression analysis
    • Six Sigma
    • Taguchi methods

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