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

Tiwari, M. K., Kumar, Maneesh ORCID: https://orcid.org/0000-0002-2469-1382 and Antony, J. 2005. An application of Six Sigma methodology to reduce the engine-overheating problem in an automotive company. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 219 (8) , pp. 633-646. 10.1243/095440505X32418

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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 $US110 000 per annum.) on the bottom-line of the company.

Item Type:	Article
Date Type:	Publication
Status:	Published
Schools:	Business (Including Economics) Centre for Advanced Manufacturing Systems At Cardiff (CAMSAC)
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management T Technology > TL Motor vehicles. Aeronautics. Astronautics
Uncontrolled Keywords:	Six Sigma; DMAIC; case study; tools and techniques; automotive industry
Publisher:	SAGE Publications
ISSN:	0954-4054
Last Modified:	21 Oct 2022 09:58
URI:	https://orca.cardiff.ac.uk/id/eprint/38569

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