PurposeThe purpose of this study is to analyze door-panel alignment defects seen in built-in ovens manufactured in one household appliances company's plant. Alignment defects in oven door panel substantially affect aesthetics of the product which is an important aspect in driving customer preference and satisfaction. Therefore, this study aimed to increase the initial 3.1 sigma level of oven-manufacturing process to at least 4 sigma level by decreasing a particular door-panel alignment defect, which constituted 67.7 percent of the overall alignment defects.Design/methodology/approachThe goals were achieved through a structured Six Sigma implementation with lean element by utilizing various Six Sigma tools such as workflow, Pareto-analysis, measurement system analyses, control-charts, process capability analysis, cause-and effect-diagram and hypotheses tests. A non–value-added step was also eliminated through the lean approach.FindingsThrough Six Sigma implementation, the initial 3.1 sigma process performance level has been increased to 4.4 sigma level leading to substantial decrease in alignment defects.Originality/valueIn the quality management literature, not many papers directly deal with aesthetics and appearance problems of the products especially in the household appliances industry. Moreover, hypothesis testing is not frequently used in Six Sigma implementations in the literature. In addition to limited usage of hypothesis testing, very few studies conducted a thorough measurement system analysis. Considering these gaps in the Six Sigma literature, this study fills an important gap in research by implementing a detailed Six Sigma study, enhanced with hypothesis testing and a thorough measurement system analysis, on the aesthetics and appearance of the product.