Title: Quality and productivity improvement using Six Sigma and Taguchi methods

Authors: M. Shanmugaraja, M. Nataraj, N. Gunasekaran

Addresses: Department of Mechanical Engineering, Government College of Technology, Thadagam Road, Coimbatore, Tamilnadu, India. ' Department of Mechanical Engineering, Government College of Technology, Thadagam Road, Coimbatore, Tamilnadu, India. ' Angel College of Engineering and Technology, Angel Nagar, Dharapuram Main Road, Tirupur – 641 665, Tamilnadu, India

Abstract: This research study proposes an innovative analysis for controlling the defects in aluminium die casting business. Six Sigma DMAIC (define, measure, analyse, improve, control) methodology is used to analyse the problem. Process validation is done with Taguchi DOE and ANOVA analysis at 95% confidence showed that the metal temperature is the vital process parameter causing defects. Confirmation experiment at optimum process parameter level showed defect level reduced from 17.22% to 4.8%. Since aluminium die casting is one of the most widely used process for producing automobile components, this study provides a methodology for improving the die casting business excellence.

Keywords: product defects; aluminium casting; die casting; blow holes; productivity; product quality; Six Sigma; DMAIC; define measure analyse improve control; statistical methods; Genichi Taguchi; experimental designs; ANOVA; analysis of variance; signal-to-noise ratios; process validation; metal temperatures; vital processes; process parameters; automobile components; business excellence.

DOI: 10.1504/IJBEX.2011.042157

International Journal of Business Excellence, 2011 Vol.4 No.5, pp.544 - 572

Published online: 27 Sep 2014 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article