R. Patidar
A.R. Madan
Abstract
In the paper is presented a Six Sigma project, undertaken within company for machining various automobile components, which deals with identification and reduction of defected items of Cab Mounting Bracket and Actuator Mounting Bracket. The objectives are achieved by application of Six Sigma approach to quality improvement project in machining industry. The work follows the DMAIC (Define, Measure, Analyze, Improve, and Control) technique to examine defects, root causes and provide solution reduce these defects. Defects rate is important as industry point of view. It plays a very important role for the improvement of defect rate & financial conditions of company. Actually defects rate causes a direct effect on the profit margin of the product & decrease the quality cost during the turning of the product. By checking & inspection of defects of product at different point in machining where more defects are happen. Maximum type of defects is found in cab mounting bracket and Actuator mounting bracket. That's why it is decided to do work & implement DMAIC methodology in machining industry. The percentage of rejection decreases from 10.09 % to 4.94 % for cab mounting Bracket and 10.97 % to 5.75 % for Actuator Mounting Bracket. The application of several Six Sigma tools such are project charter, cause and effect diagram, design of experiments, S/N ratio, and Sigma level are used. The possibility of application of several Six Sigma such as design of experiments (DOE) and analysis of variance (ANOVA) techniques were combined to statistically determine the correction of the cutting speed, feed rate and depth of cut with defects as well as define their optimum values needed to reduce the defects. Sigma Level improves after study from 2.90 to 3.16 for cab mounting bracket and 2.88 to 3.09 for Actuator Mounting Bracket.
Keywords- DMAIC approach, Six Sigma, Defects, Cause and effect analysis, Productivity, Taguchi method