These metal sheets are bought from their vendor companies mainly from Tata Steel, Bhushan Steel and Essar etc. Major steps for making the Cross Member part, we have to do various operations on the metal sheets in different compartments or shops i.e. press shop and weld shop. Drawing, Trimming & piercing (11 holes) and Trimming, Piercing & Down Flanging (13 holes) operations are done in press shop. Projection and Spot welding are done in weld shop. The process flow diagram (PFD) is shown in Fig. 2. In this pr oject the management wants to improve the process quality. Even though there are lot of checks at various stages the nonconformance
rate is 0.0357%. Management desires to estimate the Sigma level and improve the process from present level[6 -
8]