Title: Application of Six Sigma to improve quality in small scale Indian foundry industry

Authors: Mihir Solanki; Purnank Bhatt; Umangi Pathak

Addresses: Mechanical Engineering Department, G.H. Patel College of Engineering and Technology, Vallabh Vidyanagar, Anand, Gujarat, India ' Mechanical Engineering Department, G.H. Patel College of Engineering and Technology, Vallabh Vidyanagar, Anand, Gujarat, India ' Mechanical Engineering Department, Sardar Vallabhbhai National Institute of Technology, Surat, India

Abstract: In this paper, Six Sigma quality improvement methodology and computer-assisted casting simulation technique are combined to analyse gating system related defects in the green sand casting process. Six Sigma methodology enhances the process for the product selection, identification of CTQ's and root causes liable for the defects within the sand casting product. With the application of simulation software, shrinkage-porosity analysis performed for existing gating system. A modified gating system has been developed and checked for the casting defect. Several iterations have been performed with simulation software for mould filling and solidification process. As a result of the study, modified gating system has been developed and implemented and as an end result, total rejection rate has been decreased to 9.79% from an initial 27% for sand casting product, and material yield has been improved to 55.29% from an initial 44.06%.

Keywords: Six Sigma; DMAIC; sand casting; gating system; critical to quality; CTQ; defect per million opportunity; DPMO; simulation; casting defect.

DOI: 10.1504/IJSSCA.2020.112364

International Journal of Six Sigma and Competitive Advantage, 2020 Vol.12 No.4, pp.327 - 347

Received: 05 May 2020
Accepted: 14 Jul 2020
Published online: 12 Jan 2021 *

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