Title: Deployment of Lean Six Sigma in the Indian agricultural component manufacturing industry: a case study

Authors: Shubham Sharma; Rajeev Rathi; Andrei Bonamigo; João Marcos Serra de Oliveira

Addresses: Faculty of Management Sciences, School of Core Engineering, Shoolini University, Solan-Oachghat-Kumarhatti Highway, Bajhol, Himachal Pradesh-173229, India ' Department of Mechanical Engineering, National Institute of Technology Kurukshetra, Kurukshetra, Haryana 136119, India ' Federal University of Santa Catarina-UFSC, Rua Pedro João Pereira, 150, Mato Alto – Araranguá – SC, 88900-000, Brazil ' Department of Production Engineering, School of Industrial, Metallurgical Engineering at Volta Redonda – EEIMVR, Fluminense Federal University, Vila Sta. Cecília, Volta Redonda, RJ, Brazil

Abstract: This project will apply Lean Six Sigma (LSS) to a manufacturer of tractor components used for agricultural purposes to reduce waste and improve production speed and quality. The study adopts an in-depth industrial case study approach using the define, measure, analyse, improve, and control (DMAIC) methodology. Tools like value stream mapping (VSM), measurement system analysis (MSA), and failure mode and effect analysis (FMEA) were used to improve critical to quality (CTQ) parameters in the tractor's intermediate shaft. Transportation losses and defects caused most waste. Changing the shop floor layout saved 878 metres of trip distance and created 470 m² of space. 76% of rejections were treated as CTQ parameters. After improvements, shaft unit rejections went from 8.08% to 3.46% and intermediate shaft rejections from 11.83% to 4.35%, boosting sigma levels by 0.35 and 0.42. The cost of poor quality (COPQ) dropped from ₹ 539,616 to ₹ 256,256.

Keywords: Lean Six Sigma; LSS; DMAIC; measurement system analysis; MSA; failure mode and effect analysis; FMEA; value stream mapping; VSM; agricultural machinery; cost of poor quality; COPQ; India.

DOI: 10.1504/IJSSCA.2026.154300

International Journal of Six Sigma and Competitive Advantage, 2026 Vol.15 No.4, pp.389 - 412

Received: 16 Apr 2025
Accepted: 16 Dec 2025
Published online: 19 Jun 2026 *

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