DMADV Approach for Design Optimization and Quality – Application and Adaptability In Indian Automobile Industry

Paper #:
  • 2017-28-1930

  • 2017-07-10
Indian Automobile Industry has started using Six Sigma for Vehicle Design and process improvement to compete with Global competition. This Paper describes how the Tools of Six Sigma shall be used as an Effective Tool for both redefining the Design and also the Process Improvement .This Paper talks on the evolution of DMADV approach in Indian Automobile Industry compared to the related Trends in Other Manufacturing Sectors. The Author describes how the warranty failures in Commercial Segment Vehicle Category which was the selling talk for the Competition was addressed in Leading Indian Automobile OEM. As this Failure was adversely impacting customer satisfaction and no solution seemed forthcoming, top Management indicated to use a radically different approach to solve the problem within a years' time. Among the different processes evaluated, DMADV six sigma approach brought in an creative approach to problem solving and also improved systematic team work between the supplier, manufacturing function and R&D function, which were based in different demographic locations, with different work culture. This approach resulted in the goal of 10x warranty failures reduction being achieved within 10 months , besides monetary saving to the Organization. The Scope of Improvements on Engineering included redesign & Process Improvements both in Hot End and Cold End of Exhaust System and Other Interfaces @ Vehicle Level. Quality Culture evolved as Way of Life in the Process. DOE done with different Factors and Response. TRIZ principles were applied for arriving at the optimum solution. Field Evaluation Units were tried as a deviation from regular Process for expediting confidence in Decision Making. The Tool implementation also evolved 1D creation for the Optimal Design of the Exhaust Tail Pipe. The approach also being deployed for Other Improvements areas of Warranty Reduction with adaptability. In the conclusion the author talks about the Challenges ahead for extensive Application & adaptability of the DMADV approach to Other Disciplines in Auto Industry.Trends in Global Automobile Industry are also being discussed.
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