1. A company that designs Automatic Braking Systems (ABS) in the automotive industry has
introduced Six Sigma to improve product quality. Over the 2 years of application of Six Sigma
(SS) the company has made financial savings through reducing manufacturing defects.
However, the defect rate is still unacceptably high.
a) Discuss a supplementary methodology to Six Sigma that is more applicable when designing new
or existing products. Explain how this methodology could help reduce the pump defect rate
(30 marks)
b) A new ABS is being developed by the company for a new customer; this new product design has
incorporated new technology, new features and has different environmental conditions to
previous products, suggest a reliability plan and discuss how the company can ensure improved
reliability for its customer. Use the product life cycle for the timescales in your plan. You should
discuss the tasks that you have suggested in your plan and critique the key reliability tools that
would ensure optimization of the new design for reliability. You do not need to implement the
tools but explain which tools you think would be most appropriate and justify your choice.
(70 marks)
You should refer to data and information from journals or books to support your answer and
include examples to illustrate your points.
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