Author : Vikram Singh, Sushil Kumar Sharma and Irfan Khan

Six sigma is an approach to improve manufacturing process continuously. It is a disciplined and data driven approach for eliminating defects whose main purpose is to minimize the deviation between mean and target values. The numerical goal is to is to reduce defects less than 3.4 parts per million (PPM). Also known as defects per million opportunities (DPMO), reducing cycle time and reducing cost dramatically. In the present investigation, six sigma quality philosophies has been used in reduction of weld line defects in automobile tail light manufactured at Hella india lighting limited. In order to study the problem a research has carried out with the help of an engineer, by study of the six sigma and PDCA philosophies and other reference for this analysis and research method. This process include study of “Weld line” rejections utilising quality control tool, to identify the root cause of the “Weld line” rejects and to recommend action to improve the weld line reject. Before using six sigma programs, company was working at a sigma level of 4.0952. After the implementation of six sigma program sigma level was increased to 4.207, which implies that a considerable decrease in weld line defect has been achieved.

Keywords: six sigma, DMAIC, automobile tail light, defects, variations

Article published in International Journal of Current  Engineering  and Technology, Vol.3,No.4(Oct- 2013)