APPLICATION OF DMAIC TO REDUCE THE REJECTION RATE OF STARTER MOTOR SHAFT ASSEMBLY IN THE AUTOMOBILE INDUSTRY: A CASE STUDY

One of the goals of the manufacturing industry in the globalisation era is to reduce defects. Due to a variety of factors, the products manufactured in the industry may not be defect-free. Six Sigma is one of the most effective methods for reducing defects. This paper focuses on implementing Six Sig...

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Bibliographic Details
Published in:International journal of industrial engineering & production research 2021-09, Vol.32 (3), p.1-18
Main Authors: SUNDARAMALI G., Santhosh Raj K., Anirudh S., Mahadharsan R., Senthilkumaran Selvaraj
Format: Article
Language:English
Subjects:
dmaic
lean management
process monitoring and control
quality control
reliability
six sigma
Online Access:Get full text
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Summary:One of the goals of the manufacturing industry in the globalisation era is to reduce defects. Due to a variety of factors, the products manufactured in the industry may not be defect-free. Six Sigma is one of the most effective methods for reducing defects. This paper focuses on implementing Six Sigma in the automobile industrychr('39')s stator motor shaft assembly. The high decibel noise produced by the stator motor is regarded as a rejected piece. Six Sigma focuses on continuous improvement and aids in process optimization by identifying the source of the defect. In the Six Sigma process, the problem is measured and analysed using various tools and techniques. Before beginning this case study, its impact on the company in terms of internal and external customer cost savings is assessed. This case study was discovered to be in a high-impact area. The issue was discovered during the Core and Shaft pressing process. Further research leads to dimensional tolerance, which reduces the defect percentage from 16.5 percent to 0.5 percent.
ISSN:2008-4889
2345-363X
DOI:10.22068/ijiepr.32.3.13