DMADV Approach for Engineering Optimization and Quality - Application and Adaptability in Indian Automobile Industry

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 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 a creative approach to problem solving and 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 Organisation.