Dr. Vishal Bharti

Hemant Parmar

Abstract

In all processes, the slightest variation in raw material quality, production conditions, operator behaviour and other factors can cause cumulative variations (defects) in the quality of the finished product. The DMAIC approach aims to eliminate these variations and establish practices that result in a consistently high quality product. The current organization is facing a foundry rejection due to some defect, after looking at the data of the most frequently rejected Foundry Company identified were bearing housing, blower bushing, outer rings, flingers, adapter and terminal block. These blower hubs were identified as the most severely affected foundry and were therefore considered for a detailed investigation. In this study, the performance of the die casting process was improved from 3.03 σ to 3.55 σ reducing the reject rate from 6.31% to 3.98%. Having achieved such results, the top management of this industry was convinced by this initiation and decided to explore Six Sigma projects in their other processes, which is a good step in making them aware of quality

Keywords- Six sigma, DMAIC, Casting, defects, blower hub.