Title: Using Lean Six Sigma methodologies to improve operational performance in foundries

Authors: Faisal Aqlan

Addresses: Department of Industrial Engineering, Pennsylvania State University – Behrend, Erie, PA 16563, USA

Abstract: Metal casting, one of the oldest manufacturing processes, is the introduction of a molten metal into a mould where after solidification, the metal takes on the shape of the moulded cavity. The metal casting industry is a competitive, always evolving industry. While practices typically remain the same, the market fluctuates year to year. This forces companies and foundries to consistently adapt to an ever changing demand and improve their processes. To do so, foundries need to eliminate wastes in their process and ensure they produce highest quality castings. In this paper, we discuss an initiative for Lean Six Sigma process improvement in casting industry. A framework for selecting the proper problem solving methodology is presented. Several process improvement projects were identified and five projects were selected. Lean and Six Sigma problem solving methods were used.

Keywords: lean manufacturing; Six Sigma; process improvement; problem solving; casting industry.

DOI: 10.1504/IJLER.2018.093604

International Journal of Lean Enterprise Research, 2018 Vol.2 No.3, pp.173 - 188

Received: 10 Feb 2017
Accepted: 26 Jul 2017
Published online: 30 Jul 2018 *

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