In the present scenario, the Six Sigma tools and techniques are used by various manufacturing industries, exporting industries and even service organizations. It focuses on improving the quality of the products, cutting down the extra costs, reducing the variations and satisfying the customers. This case study follows the Six Sigma tools called DMAIC methodology to identify and analyze various root causes of the capacitors rejection problems, which influence the performance of the company and suggests solutions to counter with it. The issue not only causes financial loss to the company but also hinders future growth in form of customer dissatisfaction. The results of the implementation indicate significant improvement in the quality of the product and cost reduction.

Lean Six Sigma is systematic and excellent operation management approach aimed to en-hance overall production through the elimination of waste and improve customer satisfaction. In the present case study, automobile part manufacturing unit has been selected and found 22% wastage in manufacturing steps resulting reduction in production. The primary objective of this research is to find the main reasons of production wastage and recommend corresponding remedies to counter the wastage reasons. For this purpose, Lean Six Sigma approach with the help of DMAIC methodology is implemented to observe and examine different root causes of the frame lugs production losses and rejection problems. The result reveals that the movement of material and employee are critical issues for wastage of resources, ultimately affecting production of industry. Lastly, the possible solutions are to be advised to tackling these issues. The successful execution of the proposed solutions show 7% growth in the production of the component which saves annually INR 15, 64, 056.