The causes for M8 Nut failure were analyzed and found that it is due to the bad workmanship or unskilled
operator only. The material used is high quality cold rolled continuous annealed steel sheets as a raw material bought from their reputed vendor companies, mainly from Tata Steel Ltd. and others. Firstly, this raw material must be deeply examined before it is introduced in the manufacturing process. Hence defects due to material will be ruled out. The improvement can be brought into the process by proper education & training to the workers by which we can improve quality of our product. The same thing was recommended to the management. If only the M8 Nut failures in Cross Member parts were eliminated, the improvement in Sigma level will be from 5.463 to 5.632[11] Defects per Million opportunities,