IMPROVE MACHINING PROCESS CAPABILITY BY USING SIX-SIGMA


Sanjit Ray, Prasun Das

Abstract: Abstract: Six-Sigma is an improvement strategy for achieving customer satisfaction by reducing variation and thus producing products and services better, faster and cheaper. This study presents a Six-Sigma project of an automotive plant illustrating how the DMAIC methodology and statistical techniques were applied to resolve the issue of manufacturing process capability. This project has substantially benefit ted the organization by reducing the variation of bore size of cr ank case, achieving zero rejection and improving the on time delivery. By using appropriate qualitative and quantitative tools in different phases of the DMAIC methodology, the critical output, key process inputs and root c auses were ident ified, analyzed and validated. This project methodology can be used in general to reduce process variation for any other manufacturing pr ocesses as well, which will help in improving customer satisfaction.

Keywords: Six Sigma; DMAIC (Define - Measure - Analyze - Improve - Control), SIPOC; Critical to Quality (CTQ); Key Process Input Variable (KPIV); Repeatability, Reproducibility; Sigma Rating; Analysis of Variance (ANOVA)

DOI:

Recieved: 01.02.2011  Accepted: 10.04.2011  UDC: 6585.5012.7

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