Samir Telang

Prof. I.P.Keswani

Abstract

In the present scenario SIX SIGMA is a very effective statistical toolfor quality improvementwhich enhances the acceptance level up to 99.97%. Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects and minimizing variability in manufacturing and business processes. The SIX SIGMA technique which follows scientific procedure like Define Measure, Analysis, Improve and Control is utilized to solve any quality related problem. In the present work SIX SIGMA is used as a tool to identify the defect and its elimination in automobile brakes. This work was carried out in Mahindra & Mahindra, Nasik and Brakes India Ltd., Pune on newly launched vehicle "Mahindra Xylo” in the month of Dec'2008. During the testing of brakes, it was found that parking brake is facing some problem. The Parking brake lever requires more efforts to pull. The other brake performance parameterlike wear and tear ofbrake pad and rotation ofwheelstopping distance was not of desired standard. The Six sigma technique is utilized to solve the above problems and will improve the performance of brake, thus increases its demand in market. Initially quality problem is defined and all the technical related parameters were measured then systematic analysis of the components followed by corrective measures were adopted. "Component Search" of SIX SIGMA tool is used which provided the root cause of the complaint. Lastly the corrective measures taken for performance analysis was carried out which shows the significant improvement in various parameter like B versus C sample size selection etc. The economy analysis was also carried out which shows substantial cost saving with improved brake model. Thus sample points of brakes are within the limit and annual saving of Rs.21.23 lakh is achieved. Thus the improved brake model is cost effective also.

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