Article: Optimisation of defects using quality circle approach by QCFI India: a manufacturing case study of heat exchanger for automobiles Journal: International Journal of Six Sigma and Competitive Advantage (IJSSCA) 2024 Vol.15 No.2 pp.130 - 152 Abstract: Rapid changes in environmental weather conditions make air conditioning (AC) the basic need in automobiles to provide thermal comfort to passengers. AC in automobiles is a complex system consisting of heat exchangers (HEs) that play a crucial role in exchanging heat between two mediums. The manufacturing of HEs is a complex process, and during this process, many defects were generated that decreased efficiency and increased scrap cost. The main objective of the present research is to analyse and optimise these defects, a task that requires a deep understanding of the manufacturing process and the factors that contribute to defects. The approach suggested by QCFI India, and the use of Six Sigma tools has been instrumental in achieving this goal. The defects are typically generated at the point of heat applications like brazing. The minimum rejection parts per million (PPM) of the pinhole and inner leak defect was achieved by optimal setting of separator height between 21.07 mm to 21.17 mm and refluxing with potassium-aluminiflorate flux. Finally, after implementing optimal settings with several improvement configurations, the significant defects were reduced to around 85.4%. Inderscience Publishers - linking academia, business and industry through research

Title: Optimisation of defects using quality circle approach by QCFI India: a manufacturing case study of heat exchanger for automobiles

Authors: Adapa Sai Krishna; Basant Singh Sikarwar; Rakesh Kumar Phanden

Addresses: Amity School of Engineering and Technology, Amity University Uttar Pradesh, Sector 125, Noida – 201303, India ' Amity School of Engineering and Technology, Amity University Uttar Pradesh, Sector 125, Noida – 201303, India ' Amity School of Engineering and Technology, Amity University Uttar Pradesh, Sector 125, Noida – 201303, India

Abstract: Rapid changes in environmental weather conditions make air conditioning (AC) the basic need in automobiles to provide thermal comfort to passengers. AC in automobiles is a complex system consisting of heat exchangers (HEs) that play a crucial role in exchanging heat between two mediums. The manufacturing of HEs is a complex process, and during this process, many defects were generated that decreased efficiency and increased scrap cost. The main objective of the present research is to analyse and optimise these defects, a task that requires a deep understanding of the manufacturing process and the factors that contribute to defects. The approach suggested by QCFI India, and the use of Six Sigma tools has been instrumental in achieving this goal. The defects are typically generated at the point of heat applications like brazing. The minimum rejection parts per million (PPM) of the pinhole and inner leak defect was achieved by optimal setting of separator height between 21.07 mm to 21.17 mm and refluxing with potassium-aluminiflorate flux. Finally, after implementing optimal settings with several improvement configurations, the significant defects were reduced to around 85.4%.

Keywords: manufacturing defects; flux; cause and effect diagram; QCFI method; Six Sigma; heat exchangers; PPM; quality control; India.

DOI: 10.1504/IJSSCA.2024.145383

International Journal of Six Sigma and Competitive Advantage, 2024 Vol.15 No.2, pp.130 - 152

Received: 06 Jun 2023
Accepted: 31 May 2024
Published online: 31 Mar 2025 *

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Title: Optimisation of defects using quality circle approach by QCFI India: a manufacturing case study of heat exchanger for automobiles

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