Lean Six Sigma approach in an Indian auto ancillary conglomerate: a case study

E. V. Gijo*, Raniprasad Palod, Jiju Antony

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

47 Citations (Scopus)


The purpose of this article is to illustrate how Lean Six Sigma (LSS) methodology was applied to an Auto ancillary conglomerate in India for achieving operational excellence. The research reported in this paper is based on a case study carried out using LSS methodology in improving yield of a semi-automated transfer line process of the organisation. The root causes for the problem were identified and validated through data based analysis from LSS tool box, at different stages in the study. The application of LSS methodology resulted in reduction of drilling defects while machining injector bodies and reduced the Defects Per Million Opportunities from 38,000 to 5600. The application of this methodology had a significant financial impact (saving of about INR 1.4 million per annum) on the bottom-line of the company.

Original languageEnglish
Pages (from-to)761-772
Number of pages12
JournalProduction Planning and Control
Issue number9
Early online date8 May 2018
Publication statusPublished - 4 Jul 2018


  • cause and effect diagram
  • DPMO
  • Lean six sigma
  • regression analysis
  • root cause

ASJC Scopus subject areas

  • Computer Science Applications
  • Strategy and Management
  • Management Science and Operations Research
  • Industrial and Manufacturing Engineering


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