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Even supposing the technology is promoting little by little, many of the industrial operations are not advance till the finishing point their depreciation epoch due to either ignorant of cost and time reserves or inattention or overlooked. A scientific suggestion not only needs to highlight for the updating the system of manufacturing, but also needs to figure-out cost of loss in all aspects for non-upgrade of the facility. It can be done in the industrial management that to form Small Group Activity team to recognize such fatalities and remedies to resolve them. This paper discusses preparation of such valid proposal for a leading industry in Tamil Nadu. The case study belongs to a proposal of replacement machines as their depreciation period got over in an assembly plant of a largest and leading automobile manufacturer. The objective this research is to prepare the valid proposal to procure the equipment with necessary upgrades. The six sigma’s ECRS methodology is employed and majorly governs for this investigation. This study included the process evaluation, conceptual design, basic engineering design, computer aided design and validation, cost analysis. The effectiveness is verified and presented in this paper. The proposed machine reduced 70.27% of processing time, 39.02% of equipment cost and 70.25% cost per piece.