Issuu

International Research Journal of Engineering and Technology (IRJET)

e-ISSN: 2395-0056

Volume: 11 Issue: 04 | Apr 2024

p-ISSN: 2395-0072

www.irjet.net

Improving Automotive Sector using Lean Six Sigma Aaditya Kurte1, Smital Nagap2, Shivani Nalawade3, Om Hule4, Dr. Nitin Panaskar5 1Student, Dept. of Mechanical Engineering, Rajiv Gandhi Institute of Technology, Maharashtra, India 2Student, Dept. of Mechanical Engineering, Rajiv Gandhi Institute of Technology, Maharashtra, India 3Student, Dept. of Mechanical Engineering, Rajiv Gandhi Institute of Technology, Maharashtra, India 4Student, Dept. of Mechanical Engineering, Rajiv Gandhi Institute of Technology, Maharashtra, India

5Associate Professor, Dept. of Mechanical Engineering, Rajiv Gandhi Institute of Technology, Maharashtra, India ---------------------------------------------------------------------***---------------------------------------------------------------------

Abstract - The automotive industry has long been

than 3.4 defects per million opportunities. Six Sigma often uses various techniques such as DMAIC, SPC, DOE, FMEA.

characterized by fierce competition, ever-evolving consumer expectations, and the need for continuous improvement. This project delves into the application of Lean Six Sigma methodologies to bring about a transformation in this sector. The primary objectives include enhancing quality, reducing costs, and streamlining processes throughout the automotive manufacturing and supply chain. Through the DMAIC (Define, Measure, Analyze, Improve, Control) framework, this project identifies critical fac-tors affecting product quality, resource utilization, and overall operational efficiency. It integrates Lean principles to eliminate waste, enhance productivity, and minimize defects, while incorporating Six Sigma strategies to reduce process variations and enhance quality control. The utilization of various tools and techniques, including process mapping, statistical analysis, root cause analysis, and continuous monitoring, drives evidence-based decisionmaking. The expected outcomes of this project encompass substantial improvements in product quality, increased customer satisfaction, and significant cost reductions. Further-more, a cultural shift towards continuous improvement is anticipated, promoting a proactive approach to addressing issues and achieving long-term success in the automotive industry.

1.1 Techniques in Six Sigma 1. Brainstorming: Brainstorming is an integral part of the problem-solving process and is frequently utilized in the "improve" phase of the DMAIC methodology. It serves as a crucial preliminary step before the application of any specific tools. Brainstorming entails the exchange of ideas and the generation of creative solutions through open and uninhibited group discussions. Typically, a facilitator, often a lead Black Belt or Green Belt, moderates these brainstorming sessions among participants. 2. Root Cause Analysis/The 5 Whys: This technique is employed to uncover the fundamental causes of the issues under consideration and is an essential component of the "analyze" phase in the DMAIC cycle. In the 5 Whys technique, the question "why" is repetitively asked, leading to a deeper understanding of the core issue. While "five" is a rule of thumb, the actual number of questions can vary to obtain a comprehensive insight. 3. Voice of the Customer: This process is designed to capture customer feedback, often termed the "voice of the customer," through internal or external means. The aim is to provide customers with the best products and services by continuously understanding their evolving needs through direct and indirect methods. The voice of the customer technique is primarily used in the "define" phase of the DMAIC method, helping to refine the problem definition.

Key Words: DMAIC, Critical Path Method, Optimization

1.INTRODUCTION Six Sigma is a quality management approach with the primary goal of enhancing the quality of products and services through the identification and removal of defects. It is used in the automotive industry to improve the quality of vehicles and manufacturing processes, reduce costs, and increase efficiency. This is a data-centric strategy that employs statistical tools and methodologies to pinpoint and eradicate sources of variation, ultimately enhancing overall performance. Six Sigma can be applied to various aspects of the automotive industry, such as design, engineering, production, and service. Companies like Motorola started using six sigma techniques in the 1980s which was later popularized by Toyota and General Electric. The term Six Sigma refers to statistical measure of process performance where the goal Is to not have more

Impact Factor value: 8.226

4. The 5S System: Rooted in Japanese workplace principles, the 5S System focuses on eliminating waste and streamlining inefficient tools, equipment, or resources in the workplace. It consists of five steps: Seiri (Sort), Seiton (Set In Order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain).

1.2 Advantages of Six Sigma 1.Improved Quality: Six Sigma methodologies focus on reducing defects and errors, leading to higher product and service quality.

ISO 9001:2008 Certified Journal

Page 1693