SIX SIGMA APPLICATION IN MANUFACTURING SPECIAL PROCESS: A CASE STUDY ON RESISTANCE WELDING

Six sigma is the renowned process improvement strategy first started its journey from Motorola-USA. After its huge success over there, its application spread across the globe in manufacturing & service industries. The presented case study is the application of Six sigma in resistance welding process for defect prevention. The DMAIC methodology is used in the project, which is led by green belt. The paper discussed the different phases of Six sigma implementation with the application of relevant tools and techniques. The project team has identified different causes based on the collected data and classified based on their nature. The top contributing causes are identified and tested. DOE played a major role in validation of causes and identification of solutions. Finally, the solutions are implemented, monitored, and controlled to achieve the desired results. The project results which is an excellent zero-defect achievement is presented in the end.