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One of the major concerns for industries in the modern world is to focus efforts on producing high quality products with minimal costs. Various quality improvement philosophies have emerged in recent times, Six Sigma being one of the most practical and efficient techniques for quality improvement of processes. In this work, Six Sigma based DMAIC (Define, Measure, Analyze, Improve, Control) approach is used to enhance productivity and quality performance, and to make the hot forging process robust to quality variations. Finite element method has been employed for the simulation of hot forging of the connecting rod. The influence of design and process parameters is investigated for the response ‘forging die load’. Analysis of various critical parameters and the interaction among them has been carried out with the help of Taguchi’s method of experimental design. To further optimize the response and make the analysis more precise and robust, response surface methodology has been incorporated. Parameters have been optimized, leading to the accomplishment of a minimized forging die load which is verified using a confirmation experiment. Confirmatory results reveal the potential of the DMAIC approach of Six Sigma in optimizing the process parameters successfully and thereby present significant applicability in the industry.