Abstract
In the era of liberalization and open global market economy, Each and every organization wants to produce and deliver good quality products at a minimum price in order to remain competitive in the markets .To achieve this objective one must pay proper attention to their quality and lean manufacturing practices and aim for zero defects in their organizations. In the present work a new methodology namely LED3 (Lean embedded D3) methodology is applied to address the quality issue in starter motor manufacturing company. The root cause for failure of starter motor was successfully traced out using Ishikawa and five why analysis and a new technique was implemented to overcome the quality issue. After successfully implementing the new method the rejection rate has come down drastically from 7% to less than1% and Cycle time reduced from 1min to 30 sec. Total 3 hours saved per day.
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