International Journal on Recent Technologies in Mechanical and Electrical Engineering (IJRMEE) ISSN: 2349-7947 Volume: 4 Issue: 4 10 – 13 _________________________________________________________________________________________ 10 IJRMEE | April 2017, Available @ http://www.ijrmee.org _______________________________________________________________________________________ Reduction in Repair rate of Welding Processes by Using DMAIC Pawan 1 Post Graduate Student Department of Mechanical Engineering Mewar University Chittorgarh Rajasthan, India singh19031992@gmail.com Dinesh Kumar 2 Assistant Professor Department of Mechanical Engineering Mewar University Chittorgarh Rajasthan, India dinesh@mewaruniversity.co.in Kapil Nahar 3 HoD & Assistant Professor Department of Mechanical Engineering Mewar University Chittorgarh Rajasthan, India hodmech@mewaruniversity.co.in Abstract— Six Sigma is being Implemented all over the world as a successful quality improvement methodology. Many companies are now days are using Six Sigma as an approach towards zero defects. This article provides a practical case study regarding the implementation of Six Sigma project in a welding facility and discusses the statistical analysis performed for bringing the welding processes in the desired sigma Limits. DMAIC was chosen as potential Six Sigma methodology with the help of findings of this methodology, First identified the critical factors affecting the process yield and then certain improvement measures were taken to improve the capability of individual welding processes and also of overall welding facility. This is an exploratory research. The research methodology incorporated qualitative & quantitative research instruments. A comparison is done between various process excellence initiatives. An integrated methodology using the tools, techniques and skills from lean principles and Six Sigma is necessary to optimize business process. Keywords- Six Sigma, Variable control chart, Pareto charts, Standard deviation, Critical to Quality (CTQ), Analysis of Variance (ANOVA), DMAIC. ***** I. INTRODUCTION All over the world many companies are adopting six sigma methodology as process excellence tool. GE, Motorola, ABB, Citi Bank, Ford is few of them. Some Asian companies are also have been implemented six sigma. Toshiba, Honda, Sony and Samsung are few of them. Six Sigma is data driven method to achieve near perfect quality. It was started by Bill Smith in mid of 1980. It is the set of practices originally developed by Motorola to systematically improve process by eliminating defects. Defect is defined as nonconformity of a product or service to its specification. A new and improved quality improvement approach called Six Sigma is also becoming popular in controlling the defect rate and managing the quality as overall process function. The term Six Sigma refers to a highly capable process that can produce products within specifications. Process that achieves Six Sigma levels produces only 3.4 defective products per million opportunities. Main focus of Six Sigma is to improve all key processes of manufacturing setup and takes quality as a function of Process Capability to produce items with in specification. TABLE1.1 Sigma level DPMO 2 308537 3 66807 4 6210 5 233 6 3.4 The basic element of six sigma like , statistical process control , ANOVA results , pareto charts and other tools that have been on reduction of rejects and enhancing the quality .Six Sigma provides a framework in which all these tools can be performed with management support. Applying six sigma technique on reduction in repair rate of welding process by using DMAIC. DM AIC is more focused on reacting, on detecting and resolving problems, while DFSS tends to be more proactive, a means a preventing problem DMAIC is for product or services that the organization offers currently, DFSS is for the design of new product or services and processes. DMAIC is based on manufacturing or transactional processes and DFSS is focused on marketing, R& D and design. Dollar benefits obtained from DMAIC can be quantified rather quickly , while the benefits from DFSS are more difficult to quantity and tend to be much more long term .It can take six to twelve months after the launch of new product before you will obtain proper accounting on the