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Manufacturing performances tend to produce defects due to various reasons which can be improved by identifying and eliminating them using six sigma. In the present work, DMAIC (Define, Measure, Analyze, Improve and Control) has been used to reduce the number of vehicle engine rejection. In define phase problem was defined by selecting the core issues concerned. In the measure phase data was collected to determine the current performance and the process capability. During Analyzing phase root causes of engine rejection were identified. In the improvement phase solutions were arrived at and finally in the control phase various tools were implemented for tracking the process and putting it under control. The study reports process quality improvement through reduction in defects, from 7243 ppm to 687 ppm. Cost of poor quality (COPQ) has been significantly reduced from $ 30, 000 to $ 9, 000 per annum, a reduction of 333%.