Six Sigma Applications: Enhancement Sigma Level towards Quality Improvement at Automative Company

Achieving high rate of performance is one of the aims in any organizations, especially under the pressure of competition. This paper presents the implementation of DMAIC Six Sigma Methodology in automotive industry. This project is focused on a critical product which is T605039-003. The objective of the project is to increase the sigma level of the process to 3.5σ. The project started with define phase which is problem identification. Pareto analysis was conducted to find out the critical defect for part T605039-003. As a result, defect of burr at thread was selected for further study. The existing process sigma level is 3.02σ. Measurement System Analysis (MSA) was carried out to validate the measurement system used. Next, the study continues with measure phase. GR&R study is conducted to verify the capability of the measurement equipment and from the result, most of the variation is due to the differences between parts and very little is due to measurement system error. This brings the project to the fourth phase which is the improve phase. A new process is developed to eliminate burr at thread from occurring. The percentage of reject is reduced to 1.59% whereas the sigma level is increased to 3.54σ.