Title: Implementation of a Six Sigma strategy for process improvement in the wiper motor manufacturing industry

Authors: Santosh B. Rane; Prathamesh R. Potdar; Mittal Mewada

Addresses: Sardar Patel College of Engineering (SPCE), Munshi Nagar, Bhavans Campus, Andheri-West, Mumbai-400058, India ' Sardar Patel College of Engineering (SPCE), Munshi Nagar, Bhavans Campus, Andheri-West, Mumbai-400058, India ' Sardar Patel College of Engineering (SPCE), Munshi Nagar, Bhavans Campus, Andheri-West, Mumbai-400058, India

Abstract: The small and medium scale manufacturing industries in India faced many problems in real life due to financial constraints, business uncertainty, and demand fluctuations, which cannot be solved by adopting standard solutions only. Therefore, it is necessary to quickly and efficiently meet customers' changing demands by adopting business excellence practices. This study discussed the Six Sigma approach using define-measure-analyse-improve-control (DMAIC) methodology and developed tailor-made solutions (improvement measures) based on lateral thinking to solve the issues related to the manufacturing of the vehicle's electric P20 wiper motor. The suggested improvement measures have finally achieved a 38% reduction in the rejection rate and total cost saving per annum Rs. 1,249,920. This study concludes that the DMAIC methodology is a compelling set of tools to give the dramatic business results methodically and the car manufacturing company appreciated this Six Sigma initiative at the vendor's company in the production of wiper motors.

Keywords: Six Sigma; define-measure-analyse-improve-control; DMAIC; shaft concentricity; bearing fitment procedure; noise of wiper motor; assembly lines of electric motors; cause and effect matrix; process capability sixpack.

DOI: 10.1504/IJSSCA.2021.120219

International Journal of Six Sigma and Competitive Advantage, 2021 Vol.13 No.1/2/3, pp.241 - 270

Received: 30 Jul 2020
Accepted: 24 Nov 2020
Published online: 11 Jan 2022 *

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