The spares distribution centre is an important member of a manufacturing supply chain where the automobile components are packaged and distributed to customers and retail units. Though the components do not undergo processing in a spare parts centre, various other operations are performed during distribution that contributes to component failures. The Six Sigma DMAIC framework is used for the analysis of the failures effectively. The different causes of rejections are generated using the cause and effect diagram and each of these causes are validated with the help of experiments and other tools. The root cause of this problem arising in the distribution centre is identified to be the packing method. An economic solution to the existing cause of the problem is implemented with minor variations in the current packing method and the results are discussed. A structured follow up plan for continuous improvement is also suggested. © Copyright 2018 Inderscience Enterprises Ltd.