Assignment 1

Name Muhammad Saad Mubeen

Registration Number FA23-MSSE-005
Semester 2nd
Subject Software Measurement and Metrics
Submitted to Dr. Amber Sarwar
Muhammad Saad Mubeen FA23MSSE005 Assignment 1

Q: Apply Six Sigma DMAIC methodology for process improvement analysis to the following
case study.
The rejection rate of the rubber weather strips manufactured by XYZ Ltd. was significantly
high and was more than 5%, which was causing huge financial loss to the industry. Customer
satisfaction was also affected because of the high rejection rate of weather strips. The quality
assurance section of the industry decided to minimize the high rejection rate of the rubber
weather strips using the Six Sigma DMAIC approach. The DMAIC methodology used in this
project is categorized into the following five basic phases:

• Define: Define the problem and goal of the project (Problem and goal statement
worksheet).
• Measure: To examine the current status of the problem.
• Analyze: Analyze the current situation and find out the solution to achieve the goal.
• Improve: Implementation of the solution to achieve the goal.
• Control: Make sure that permanent improvement takes place.
Which tools and techniques will be used for each phase for the given case study.

Solution:
Define:
• Problem Statement:
o High rejection rate (over 5%) of rubber weather strips causing financial loss
and customer dissatisfaction.
• Goal Statement:
o Reduce the rejection rate of weather strips to a target level (e.g., 3% or less)
within a specific timeframe (e. define timeframe).
• Tools and Techniques:
o SIPOC Diagram: This helps visualize the process by identifying Suppliers,
Inputs, Process, Outputs, and Customers.
o Voice of the Customer (VOC): Gather feedback from internal and external
customers (assembly line workers, end users) to understand their needs and
quality expectations for the weather strips.

Measure:
• Data Collection:
o Collect data on rejection rates, type of defects, and their frequency over a
period. This could involve control charts, Pareto charts, and defect tracking
logs.

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Muhammad Saad Mubeen FA23MSSE005 Assignment 1

• Cause and Effect Diagram (Ishikawa Fishbone):

o Identify potential causes of rejections by brainstorming and categorizing them
(e.g., materials, machines, methods, manpower, measurement).

Analyze:
• Pareto Chart:
o Analyze the collected data to identify the most frequent defects causing most
rejections (80/20 rule).
• Failure Mode and Effects Analysis (FMEA):
o Analyze the impact and likelihood of potential causes identified in the Cause-
and-Effect Diagram.

Improve:
• Brainstorming:
o Develop solutions to address the root causes of the most frequent defects
identified in the Analyze phase.
• Pilot Implementation:
o Test the most promising solutions on a small scale to evaluate their
effectiveness before full-scale implementation.

Control:
• Standardization:
o Develop and document standard operating procedures (SOPs) for the
improved process.
• Control Charts:
o Implement control charts to monitor the performance of the improved process
and detect any deviations from the target rejection rate.
• Continuous Improvement:
o Regularly review the process and data to identify opportunities for further
improvement.

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