Six Sigma Methodologies for Increasing the First Pass Rate of Engines in Manufacturing

Abstract

The purpose of this paper is to show the use of the Six Sigma methodology in improving the first pass rate of an ALH4CT engines during manufacturing. The paper follows case study, design and manufacturing approach. The case study was performed in a leading automotive based company in India. The application of the Six Sigma methodology resulted in a reduction of tolerance-related problems and improved the first pass yield from 95 to over 99 percent. A number of tools and techniques in the Six Sigma tool box have been utilized for data analysis and drawing valid and sound conclusions. Using Pareto analysis, the primary causes for each of the defects were analyzed. As per the analysis, it is absorbed that the loss of power due to wrong flywheel marking was the major cause for engine rejection. The fixture of the rotary table has been modified by placing a sleeve in the dwell pin locator. This sleeve used to reduce the play between the flywheel and the table. This in turn would correct the flywheel marking, thereby increasing the pass of percentage. The results of the case study have provided greater stimulus within the production facilities for wider application of the methodology as a powerful problem solving methodology. Keywords: Six Sigma, Business Process Improvement, Automotive Industry, Change Management, Data Analytics How to cite this article: P Pathmanaban, B Naresh, Ganesh SS et al. Six Sigma Methodologies for Increasing the First Pass Rate of Engines in Manufacturing. J Adv Res Qual Control Mgmt 2019; 4(1): 24-30.