Product development using Design for Six Sigma approach: case study in switchgear industry

The competitive business environment conditions of market have compelled to reduce the development period of products; therefore, organizations are more focused on optimizing product development period to satisfy customers' needs quickly. This study aims to shorten the development period of moulded case circuit breaker (MCCB) using design for Six Sigma (DFSS) approach and ensure sustainable product development using reliability analysis. In this study, the DFSS approach has been demonstrated using define measure analyze design and verify (DMADV) methodology with appropriate tools and techniques at each stage for the development of MCCB. The mechanical endurance test (MET), electrical endurance test (EET) and temperature rise test (TRT) have been performed to ensure the sustainability of the developed MCCB. The comparative analysis of the TRT results of the existing and uprated MCCB shows the reduction in temperature rise by 10 degrees C at the terminal. The efforts and time required for product development have been reduced due to the uprating of existing MCCB and reliability of uprated MCCB is computed as 98.44% by analyzing collected data using Weibull distribution. The analysis shows the wear-out failure of MCCB components as the shape factor value of the Weibull distribution is greater than one. This study concludes that every organization should critically reinvestigate the product to explore the opportunity for improving the quality and functionality of the product using appropriate tools and techniques. This case study clearly shows improvement in product reliability and quality which results in cost-saving business.