Use of six sigma method as a process improvement technique

This thesis suggested a conceptual Six Sigma/DOE hybrid framework aiming to integrate Taguchi methods and Six Sigma for process improvement in a complex industry environment. The studies employing the Taguchi experiment design usually focus on a single variable and neglect the effects of the adjustments on remaining quality characteristics, in this study a multi-response experiment design was preferred and all of the quality characteristics are taken into account. The aim of this study is the implementation of Six Sigma methodology on a company operating within the automotive industry and the statistical evaluation of the methodological effects on the performance of the enterprise. This Six Sigma study was conducted to improve the manufacturing process which caused a customer complaint within the company. DMAIC phases are used to reduce the nonconformity rate from 23.940 percentage (baseline) to 0.049 percentage. As the result of implementing SS, the sigma level increased from 2.21 (baseline) to 4.80.