Lean Six Sigma implementation in an OEM: a case-based approach

Abstract

Lean Six Sigma (LSS) is a successful quality improvement program. However, many pieces of literature have reported that companies have struggled with LSS projects and Indian manufacturing firms are no exception to this scenario. Therefore, this article describes LSS implementation at a manufacturing company. The company manufactures power take off (PTO) shafts for tractors. Nevertheless, the company was receiving high non-conformance resulting in part rejection. Therefore, the study deals with the defect reduction through LSS implementation. Using the DMAIC approach with suitable tools, statistical analyses were performed to identify the bottleneck in the operations, and the corrective measure was taken to improve the quality of PTO. In addition, the researchers proposed preventive methods for reoccurring issues and developed a plan to sustain the project to find the required results. At the end of the project, the researchers yielded considerable cost saving and defect reduction. The study concludes with the managerial implications and contribution to the society with the limitations of the study.