Six Sigma as Quality Improvement: An Insight from Disc Front Brake Manufacturing

Abstract

This study investigates the applicability of the Six Sigma technique to the automotive industry's disc front brake production process. The study applies the DMAIC (Define, Measure, Analyze, Improve, and Control) methodology to identify and repair flaws in the production process, hence boosting product quality and minimizing defects and process irregularities. Using statistical analysis and Six Sigma technologies, the inquiry aims to determine the critical process parameters influencing product quality in partnership with significant manufacturing facilities. The anticipated results include a reduction in faults, an increase in process stability, potential cost savings, and an improvement in vehicle safety. This study focuses on improving the quality and efficiency of production processes, and it examines the most recent technological developments and advancements in the automobile industry. The research findings reveal a rejection rate of 3.45 percent, with various rejection categories including dents, "Goyang," "Getar," diameter inconsistencies, and steps. These rejections are caused by a variety of factors, including dirty reference points, material impacts, and inadequate adhesion in cases of misalignments. Additional suggestions for reducing rejects include the implementation of training programs, documentation, the establishment of new Standard Operating Procedures (SOPs), the creation of machine maintenance checklists, the scheduling of coolant box drainage, the adoption of new target setting cycles, and the utilization of checklists as control measures.