ABSTRACT

Assembly line process improvement based on Lean Six Sigma with approach is an area o technical interest. As it involves the globally recognized solution provided by Lean and Six Sigma for process improvement with their tools and techniques. The Lean Six Sigma jointly executes its impact with the famous strategy employed with DMAIC (Define, Measure, Analyze, Improve, Control) cycle in order to resolves issues and eliminates problems within a Assembly Line process and operations. Through its implementation one can enhance its overall product quality, with improved profit and better customer satisfaction achievement.

The research and process improvement work hard its objective firstly, to get known to the Lean Six Sigma and its actual implementation over an automotive assembly line where improvement is required. Secondly it was felt necessary to initially develop knowledge of implementation of Lean Six Sigma vis DMAIC approach for online improvement of manufacturing operations. The ultimate objective is to minimize Work in Process (WIP) and Lead Time or Cycle Time which in turn enhance the overall performance, efficiency and product quality with consent customer satisfaction.
While for such objectives the DMAIC approach was best suitable as, it is best suited for the
operation where the product is already under operations and the process improvement needs to be done without any stoppage to operations. As the original manufacturing method is still in
practice while it needs to be improved with knowledge based approach of Lean Six Sigma. Hence it was observed that the process had many qualitative and quantitative discrepancies with
many variations in process due to certain reasons explained further which were than analyzed and taken under considerations for process improvement.