Application of DMAIC for Process Industry: A Case Study

The present work deals with application of DMAIC for minimization of sand casting defects in a process industry. DMAIC approach is justified when root cause of defect is not traceable. At present, global and competitive environment, foundary industries need to perform efficiently with minimum number of rejection in their manufacturing products. For better improvement in the casting quality, first of all finding the root causes of occurrence of defects blow hole in the casting process and taking necessary step to reduces defects and hence rejection in casting. Six sigma is more than a quantitative statistical measure of processes; it embraces every aspect of work, using a disciplined, fact based approach of problem-solving. Many time defects occur due to variation in the process parameter which are very difficult to detect. In the present work the metal casting process is analysis and minimised by using DMAIC (Define, Measure, Analysis, Improve, and Control) approach. Through a case study in a medium scale faundary, the present work formulate a comprehensive strategy of six sigma in indianfoundary. This study has significantly increase the efficiency of foundry industry and reduce scrap and waste in sand casting process which improve the production efficiency.A number of experiments are carried out to validate the results which indicate that the cost of experimentation will be less, in comparison to the gain or profit of the company.The results achieved shows that the rejection due to blow hole defects has been reduced from 5.83% to 2.04% which saved the cost of Rs 23828/monthly (for continuous four months), in a turnover of 60 lakhs. INTRODUCTION: Present study was done at SWASTIK INDUSTRIES KAITHAL,HARYANA on application of Six Sigma methodology and Selection of tools and techniques for problem solving, because the rejection rate is very high. The present case study deals with reduction of rejection due to casting defects in a foundry industry. The industry is making cast iron castings of submersible pumps components such as Upper housing, Motor Pulley, Mini Chaff cutter wheel\Hand wheel in large scale and having rejection in the form of Blow hole, Misrun, and slag inclusions. The DMAIC is both a philosophy and a methodology that improves quality by analyzing data, to find root cause of quality problems and to implement controls. Although DMAIC implemented to improve manufacturing and business, processes such as product design and supply chain management. It is a business improvement strategy used to improve profitability to drive out waste in business process and to improve the efficiency of all operation that meet or exceed customer’s needs and expectation. DMAIC is a IJSER International Journal of Scientific & Engineering Research, Volume 6, Issue 5, May-2015 111 ISSN 2229-5518