UNIVERSITY OF ENGEENIRING

TECHNOLOGY NEW CAMPUS

TOPIC: MQA CEP

SUBMITTED TO: Mr.’s Samina
SUBMITTED BY
ROLL NO. NAME

2018-ME-352 Abdullah Mobeen

2018-ME-362 Sami-ur-Rehman
2018-ME-364 Saffi Ul llah Tanveer
2018-ME-384 Hamza maqsood

SECTION: B
DEPARTMENT: Mechanical Engineering
Scenario
Six Sigma is an effective quality system and widely deployed in manufacturing. That mainly
concentrates on measuring product/service quality, reducing variation, driving improvements and
saving the cost. Implementation of Six Sigma methodology had a significant financial impact on
the profitability of the company. The impact of Six Sigma and its dependence on organizational
structure, organizational culture, leadership role, social embeddedness, role stress etc. are
identified as areas for future research. Successful implementation of Six Sigma methodology in a
high precision and critical process in the manufacture of automotive products is an essential
need. Use a planned approach by using DMAIC process to find the possible results regarding
data collected from a manufacturing industry. The possible constraints to perform the problem
are as follows;

Constraints

● To eliminate nonconformance in terms of defective parts and calculate annual yield.

● Developing a plan for a manufacturing industry to optimize its cost.
● Cause and Effect Relationship diagram
● Pareto Chart to illustrate the vital few and useful many attributes.
● Develop regression analysis, hypothesis testing
● Conclude your results based on abovementioned constraints.

Attributes

● Depth of knowledge
● Range of conflicting requirements
● Depth of analysis required
Industry:
We are implementing six sigma plans using DMAIC approach for the Honda Motors. This plan
will help out to identify the problem, measure the problem and its cause and effects, Analysis of
causes and effect, improve the defective parts and vital cause and control the defects. And this
includes define, measure, analyze, improve and control
Measure:
During this phase, we select the most critical and impactful opportunities for improvement. This phase is
also about mapping the process, focus, scope, and the ultimate goal as well as understanding how the
problem affects all stakeholder. In our case study we have a defective part that is defective car door. This
defective part has critical effect on customer.

No# Defects Defect Cumulative Cumulative

frequency frequency
%

1 Counter miss 56 56 28

2 Hole miss 48 104 52

3 Reverse bending 27 131 65.5

4 Side hole error 21 152 76

5 Drill out 14 166 83

6 bend 11 177 88.5

7 Heavy tool mark 9 186 93

8 Side crack 7 193 96.5

9 Bush hole miss 3 196 98

10 Taper error 2 198 99

11 Taper cut miss 1 199 99.5

12 Center hole 1 200 100

----- Total =
200

In this phase we measure the cause and effect of car roof sheet as a defective part.
Effect is lower finishing quality, less customer attraction, additional labor cost and additional paint
Cost.
Analyze:
The Measure phase is where baselines are drawn to assess the performance of a given process. Without
having sound benchmarks for comparison, it’s difficult to track improvements. Hence, at this stage, we
Develop the data collection methods to be used to measure success
Recognize input, processes, and output indicators
Collect and examine current state data
Outline the failure modes and Cause - effects analysis
Implement process capability analysis
cost of defective parts will be optimizing by focusing on the vital few defects that have more
than 80 % effect. Now by using the pareto chart we analyze vital few and useful many attributes.

Vital few

No. of
defects
From pareto chart we have a clear that we have to improve the vital few defect that can cause 80% effect
● Counter miss
● Hole miss
● Reverse bending

Cause and effect diagram;

Regression analysis and hypothesis test:
Regression analysis is a way of predicting future happenings between a dependent (target) and one
or more independent variables.
The main uses of regression analysis are forecasting, time series modeling and finding
the cause and effect relationship between variables.
Now This will lead To Customer satisfaction.

And as For Hypothesis analysis is the process of using statistics to determine the probability that a
specific hypothesis is true. Hypothesis testing is categorized as parametric test and nonparametric test.
Results:
From the above DMAIC analysis we have concluded that the surface defects on the roof of car is
due to vital few that are mentioned in the pareto graph
From the DMAIC we can easily identify the problem and can easily sort out it and fix it to
improve our manufacturing process and ultimately can optimize the part cost.
Comments:
● Six sigma is an effective way to figure out where are the greatest process needs and
which are the softest points of the process.
● Also, six sigma provide measurable indicators and adequate data for analytical aanalysis.
● Definitely, Six Sigma is a powerful methodology that can, properly implemented, result
with significance savings and improvements.
● Quality control is important in nearly every industry. It ensures that each product
leavingthe factory is of the highest quality and the same as all those items that came
before it. One industry where quality control is especially vital has benefits as,
Higher productivity
Lower costs / shorter duration
Higher project team morale
Fewer errors / defects
Reduce liability risks.