To Implement “Lean Six Sigma” Concept in Automobile Manufacturing – A Case Study

Abstract

With the ever increasing demand of the customer in a highly competitive environment quality perfection is a desirable objective. The purpose of this paper is to bring the focus on problem solving techniques using Lean Six Sigma methodology and to change the mind set of peoples within the organization that root cause cannot be established just by thinking and engineering guesses. Six Sigma methodologies help to pin root causes using simple data collection and analysis technique. This case study will explain the application of various graphical and statistical tools of problem solving in real life like Pareto, Box Plot, Main effect plot, Interval plot and Binary logistic regression. The study was conducted at M/S Asahi India Glass an auto glass manufacturer a Tier 1 supplier of Maruti Suzuki India Limited (Largest Car Manufacturer of India). The major pain area was high rejection in Tempering process i.e. 62158 PPM against the target of 45000 PPM in FY 2013-14. With the scoping tools like tree diagram and Pareto, Product Backlite glass of Swift Dzire (MPG-BCK) was found the major contributor and characteristics identified for analysis were Curvature NG, Blast Head Breakage, and Roller Imprint. This rejection was being reported since inception. As a result by this case study after analysis and countermeasures the overall rejection reduced by 40%.