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

E. V. Gijo; Raniprasad Palod; Jiju Antony

doi:10.1080/09537287.2018.1469801

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

School of Social Sciences

Research output: Contribution to journal › Article › peer-review

52 Citations (Scopus)

Abstract

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 language	English
Pages (from-to)	761-772
Number of pages	12
Journal	Production Planning and Control
Volume	29
Issue number	9
Early online date	8 May 2018
DOIs	https://doi.org/10.1080/09537287.2018.1469801
Publication status	Published - 4 Jul 2018

Keywords

cause and effect diagram
DMAIC
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

Access to Document

10.1080/09537287.2018.1469801

Cite this

@article{17746cf9ea844e629ac6c03c4eab9791,

title = "Lean Six Sigma approach in an Indian auto ancillary conglomerate: a case study",

abstract = "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.",

keywords = "cause and effect diagram, DMAIC, DPMO, Lean six sigma, regression analysis, root cause",

author = "Gijo, {E. V.} and Raniprasad Palod and Jiju Antony",

year = "2018",

month = jul,

day = "4",

doi = "10.1080/09537287.2018.1469801",

language = "English",

volume = "29",

pages = "761--772",

journal = "Production Planning and Control",

issn = "0953-7287",

publisher = "Taylor & Francis",

number = "9",

}

TY - JOUR

T1 - Lean Six Sigma approach in an Indian auto ancillary conglomerate

T2 - a case study

AU - Gijo, E. V.

AU - Palod, Raniprasad

AU - Antony, Jiju

PY - 2018/7/4

Y1 - 2018/7/4

N2 - 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.

AB - 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.

KW - cause and effect diagram

KW - DMAIC

KW - DPMO

KW - Lean six sigma

KW - regression analysis

KW - root cause

UR - http://www.scopus.com/inward/record.url?scp=85046687134&partnerID=8YFLogxK

U2 - 10.1080/09537287.2018.1469801

DO - 10.1080/09537287.2018.1469801

M3 - Article

AN - SCOPUS:85046687134

SN - 0953-7287

VL - 29

SP - 761

EP - 772

JO - Production Planning and Control

JF - Production Planning and Control

IS - 9

ER -

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

Abstract

Keywords

ASJC Scopus subject areas

Access to Document

Other files and links

Fingerprint

Cite this