Cummins Six Sigma Project Results in a Smoother Ride for Dodge Ram Pickup

Case Study

- September 2006

Abstract: During an executive test drive just months before product launch, Daimler Chrysler officials declared a no-launch decision because of excessive vehicle vibration for the company's newly designed Dodge Ram Mega Cab 4x4 pickup. Cummins Inc., manufacturer of the truck's diesel engine, immediately chartered a Six Sigma team and employed the DMAIC problem-solving process to diagnose and correct the factors leading to the high vibration levels. Through extensive testing, the Six Sigma team determined that by increasing the crankshaft counterweight radius, vibrations were significantly reduced. The Cummins' team completed the DMAIC project in an extraordinary time frame—just over four months—resulting in a 16% reduction in vibration levels and a 100% increase in sales of the truck in the first year compared to sales projections.

Keywords: Case study - Six Sigma - Define-measure-analyze-improve-control (DMAIC) - Business results - Customer focus - Root cause analysis - Problem-solving

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