Operations management

Excellence

Machining

Sedimentary rock

Manufacturing engineering

Engineering

Operational excellence

Biology

Political science

Conglomerate

Lean manufacturing

Six Sigma

Lean Six Sigma

Paleontology

Mechanical engineering

Production Planning & Control

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.

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