Title: Cost of poor quality reduction in auto sector: an exploration with Six-Sigma

Authors: Sourabh Kumar; Dinesh Khanduja

Addresses: National Institute of Technology, Kurukshetra-136119, Haryana, India ' National Institute of Technology, Kurukshetra-136119, Haryana, India

Abstract: The cost of poor quality (COPQ) always helps in analysing the operating costs for effective and profitable business management. COPQ consists of those costs which are generated as a result of producing defective material. The present study deal with implementing the Six-Sigma in the Indian automobile company. This research aims to reduce the problems faced by the company's quality inspection department. The department faces various rejection problems of two vehicles, such as front fork pivot hard movement, grease nipple broke, O-rings struck, edge bends, etc. We used a structural DMAIC methodology to improve the process. This study used multiple Six-Sigma tools such as Pareto chart, process map, fishbone diagram, and process capability chart to solve the rejection problem. Using a Six-Sigma methodology, we improved the sigma level of 1.875 to 4.375, which benefits 199,020 rupees' rework costs annually. This study helps practitioners and academicians to emphasise their effort towards COPQ.

Keywords: Six-Sigma; Pareto analysis; process capability; project planning; defects; automobile.

DOI: 10.1504/IJSSCA.2021.120249

International Journal of Six Sigma and Competitive Advantage, 2021 Vol.13 No.1/2/3, pp.271 - 288

Received: 08 Jun 2020
Accepted: 04 Jan 2021
Published online: 11 Jan 2022 *

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