A Case Study of Systematic Problem Solving (Six Sigma) to Solve an Actual Problem in a Car Manufacturing Industry

Many of the chronic problems in a car manufacturing company associated with quality, cost and delivery are the result of increased complexity in such industry. The Problem solving methods and expertise teams strives to make complexity more manageable and bring the chronic problem into solution. In present paper, the systematic and structured problem solving tools (simple six sigma tools with DMAIC cycle) and cross functional teams are used to reduce the defect of noise in 405 Peugeot cars, which was one of the most chronic defects of this car and one of the first items in final customer dissatisfaction. Such complex defect has consisted of so many sub-problems which must be solved and different parameters which must be brought under control. Using a very simple six sigma tools such complicated problem of this case study shows more than 60% DPU (Defect per Unit) improvement. The intent of writing this article is to present the reader with an actual case study for structuring and improvement of six sigma projects which does not need necessarily complex six sigma tools.

Keywords:

Iran khodro , Noise , Peugeot 405 , Six Sigma