Failure Analysis of Automotive Drive System: A Six Sigma DMADV Approach

This study outlines the application of the Six Sigma methodology to rectify oil seal leaks in an automobile company's hollow drive shafts. Persistent issues with oil seepage through the shaft's oil seal led to clutch malfunctions, power failures, and subsequent breakdowns, resulting in high warranty costs, which negatively impacted the status of a firm in the market and the level of fulfillment experienced by its clients. Projects are crucial for translating an organization's strategic goals into achievable outcomes, serving as the cornerstone of success. We implemented a quality-driven effort using Six Sigma and the Theory of Inventive Problem Solving (TRIZ) to foster a culture of continuous improvement. Utilizing the procedures-oriented DMADV (Define, Measure, Analyze, Design, and Verify) technique, the oil seal leakage issue was addressed and resolved successfully from the gearbox. The Pugh matrix was used to choose a new design from various alternatives, a KANO model to evaluate customer demands, and a cause-and-effect diagram to analyze possible failure situations. The overall aim was to determine the failure situations that were most likely to occur. Through its deployment, we intended to improve both the product's dependability and the production process's efficiency. Following the design improvements, the defects observed in the assemblies dropped to 58, with no occurrences of oil seal leakage. It is plausible to conclude that these techniques can significantly enhance product quality. The study demonstrates the efficacy of Six Sigma methodologies in tackling intricate situations.