Rectification of the improper mating of the rack and valve assembly using Six Sigma methodology at a steering manufacturing & assembly plant.

Precision automobile components and the automobile assembly systems are found to be the building element of any automobile, thus it is evident for the stakeholders to take utmost care and ensure that the most superior quality is delivered to the market. The minus cost principle says that when the quality is assured the time taken for the production is more which results in low volumes and where the volume is concerned the quality is compromised. Thus, focusing on one parameter results in the disturbance of the other. Hence, it should be balanced in such a way that the quality achieved is superior and with high volumes. While concentrating on the two parameters the parameter which is often neglected is the cost and it is found to be one of the most significant parameters for which the stakeholders have to focus upon. The following study illustrates how the quality factor was accounting for the heavy loss in a steering manufacturing company and how was the problem addressed with the most optimized solution thus eliminating the cost of poor quality. During the assembly of the steering system, three major components; the rack gear, the pinion gear and the housing are clustered and allowed to fit perfectly according to the design specification. Thus the method adopted to achieve the results was Six Sigma DMAIC Methodology. The DMAIC is an acronym for the Define Measure Analyze Improve and Control which is widely used in industries to address the problems when the problem is not easily identifiable.