Enhancement in production efficiency using DMAIC methodology of six sigma

The business concern is primarily interested in the industrial system's production efficiency from an economic standpoint. The primary sources of inefficiency and challenges stem from the decisions made about production operations, particularly in cases where machinery plays a significant role in manufacturing. The manufacturing industry is experiencing increased worldwide rivalry, which has led to a constant increase in customer demand for high-quality and varied products. As a result, improving performance and productivity is now required to strengthen the process's quality. This manuscript uses the Define, Measure, Analyse, Improve, and Control (DMAIC) technique to reduce crankshaft defects and increase quality in the manufacturing business. Quality practices from the Six Sigma DMAIC methodology can be effectively applied to produce high production rates, lower losses, and less waste. Highway Industries Limited has a forging shop that fabricates a variety of crankshaft types, including P-19, KZNA, and M2W. Crankshafts have intricate forms, and a variety of forging flaws, including pitting, unfilling, undersizing, bending, and flash defects, can occur throughout the manufacturing process. The results show that the overall rejection rate of the M2W crankshaft dramatically drops to 1.88% with the deployment of the Six Sigma technique, as opposed to 3.04% before implementation. This study aims to evaluate the effectiveness of the Six Sigma methodology by using the DMAIC cycle methodically. Therefore, the recommended approach saves money, which in turn helps to increase the industry's total economics.