MINIMIZATION OF REJECTION RATE USING LEAN SIX SIGMA TOOL IN MEDIUM SCALE MANUFACTURING INDUSTRY

The objective of this research is the pilot implementation of six sigma DMAIC phases to improve the rejection rate of manufacturing industry. The current global market is focusing on zero defects that are 3.34 defectives per million parts produced. Six Sigma places the emphasis on financial results that can be achieved through the virtual elimination of products and process defects. Profits and industry stakeholder value is maximized. In this research it is proposed to analyze a case study by implementing six sigma tool for minimization of rejection rate. The defect is identified by process flow, pareto chart, fish bone diagram and all were also adopted to analyze the depth of the issue and to identify the critical factors which is required for controlling and improving the overall expectations for the zero rejection rate. From the results it was found that, rejection rate of the selected manufacturing industry is brought to 1.2% from 5.3% through the implementation of DMAIC.