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This study applies Six Sigma to optimize the keyway cutting operation on a shaft of a gear box produced by Horton Automatics Company. Since the operation had not been optimized, many problems had been raised in the assembly of keys with shafts and a considerable number of scrap parts had been produced which deteriorated profitability of the company. The main problem was that the keyway width did not allow keys to be assembled into the shaft tightly. To solve the problem and optimize the process, DMAIC (Define, Measure, Analyze, Improve, and Control) methodology of Six Sigma was applied. In this paper, the steps of DMAIC to optimize the operation are presented and illustrated. In the Define phase, the problem was defined and the specific operation of the manufacturing process was recognized by the PFMEA (Process Failure Mode Effects Analysis) technique. In the Measure phase, the operation was studied and the process capability was measured. In the Analyze phase, the factors that affect the keyway width were identified by a causeand-effect analysis. In the Improve phase, the best combination of the levels of the factors was determined by using the Design of Experiments (DOE) technique and the best combination was applied. Finally, in the Control phase, some recommendations were given in order to keep the process in good condition.
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