<![CDATA[This study aims to analyze dimensional defects in electric vehicle battery bracket products using the Six Sigma method with the DMAIC approach. This descriptive quantitative study utilizes processed or simulated production data from January to August 2025, covering four critical-to-quality characteristics: Hole Position, Diameter, Flatness, and Burr/Deformation. Of 164,500 units produced, 2,125 defect occurrences were identified, resulting in an aggregate defect rate of 1.29%, a DPO of 0.003229, a DPMO of 3,229.48, and a sigma level of 4.22 based on a 1.5-sigma shift. Pareto analysis revealed that Hole Position defects were the most dominant at 40.56%, followed by Diameter at 24.89%, Flatness at 20.19%, and Burr/Deformation at 14.35%. Fishbone and 5 Why analyses identified potential causes, including locator jig wear, inconsistent machine setup, inadequate first-piece approval, and the absence of cycle-based locator lifespan standards. Improvement proposals were developed using 5W+1H and a control plan to support sustainable production process monitoring. As these proposals have not yet been implemented, their effectiveness requires validation through production trials and actual measurements.]]>
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