scholarly journals Analysis of Shrinkage Defect in Sand Casting by Using Six Sigma Method with Taguchi Technique

2021 ◽  
Vol 1059 (1) ◽  
pp. 012047
Author(s):  
M A Omprakas ◽  
M Muthukumar ◽  
S P Saran ◽  
D Ranjithkumar ◽  
C M Shantha kumar ◽  
...  
Keyword(s):  
Six Sigma ◽  
Sand Casting ◽  
Taguchi Technique ◽  
Shrinkage Defect

Competitive advantage through Six Sigma in sand casting industry to improve overall first-pass yield: a case study of SSE

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Mihir Solanki ◽  
Darshak Desai
Keyword(s):  
Six Sigma ◽  
Sand Casting ◽  
Small Scale ◽  
Productivity Improvement ◽  
Content Type ◽  
Foundry Industry ◽  
Road Map ◽  
First Pass ◽  
Six Sigma Methodology

Purpose The purpose of this paper is to illustrate how Six Sigma methodology has been applied in a small-scale foundry industry to improve the overall first-pass material yield and quality, with a view to the product and the process. Design/methodology/approach The researchers have reported this paper based on a case study carried out in industry using the Six Sigma Define, Measure, Analyze, Improve and Control (DMAIC) and its application in improving the manufacturing process of a foundry shop. Findings Identified root causes are validated and countermeasures are implemented for improvement. As a result of this case study, the overall first-pass yield of the sand casting process is improved to 78.88% from the previous yield of 67%. For product-specific case, yield is improved by 18% through the improved gating system design. Sigma level of the process is improved to 3.08 from baseline 2.21. Key lessons learned from this case study are mentioned in the current study. Research limitations/implications This case study provides a standard road map and motivates small-scale foundry industries to implement Six Sigma methodology for productivity improvement, especially in jobbing foundry. The presented paper is based on a single case study, and the results are limited to the company only. Also, one of the reasons for low process yield is slag creation, which is not covered here, as it is a concern of the material quality supplied by the vendor. However, the approach of this paper is generic for learning perspective. Practical implications This case study provides a standard road map and motivates small-scale foundry industries to implement Six Sigma methodology for productivity improvement, especially in jobbing foundry. Through the effective application of Six Sigma quality initiative, how a quantum jump in financial aspect could be gain, has been demonstrated. Originality/value This research study showcases step-by-step implementation of Six Sigma-DMAIC methodology at a small-scale foundry industry. This paper could serve as a unique roadmap for practitioners and academicians to improve the material productivity of the foundry industry both ways, product and process.

Application of Taguchi-based Six Sigma method to reduce defects in green sand casting process: a case study

2019 ◽  
Vol 13 (2) ◽  
pp. 226
Author(s):  
Mahantesh M. Ganganallimath ◽  
Suraj Dhondiram Patil ◽  
E.V. Gijo ◽  
Roopa B. Math ◽  
Vijaykumar Hiremath
Keyword(s):  
Six Sigma ◽  
Casting Process ◽  
Sand Casting ◽  
Green Sand

scholarly journals Defect Analysis and Process Parameter Optimisation in Sand Casting

2020 ◽  
Vol 9 (6) ◽  
pp. 390-395
Keyword(s):  
Hot Spot ◽  
Metal Flow ◽  
Casting Process ◽  
Process Parameter ◽  
Sand Casting ◽  
Cover Plate ◽  
Small Scale ◽  
Design Calculation ◽  
Defect Analysis ◽  
Shrinkage Defect

M/s. Boparai Metals, a small scale industry situated in Industrial Area, Mohali, Punjab is manufacturing and supplying automotive and non automotive component to tractor companies in Punjab and aiming to provide the best solutions. The company is facing the problem of castings defects i.e. porosity, hot spot and shrinkage in cooler plate during the Sand Casting process. In this work, the study of existing process was done to find the root cause of the problem. Three dimensional gating system of cooler cover plate were modified by using UG– NX software. The models were imported using ADSTEFAN software for simulation of SAND-CASTING process. Based on the specification of cooler cover plate material, cast iron moulds in the green sands and input process parameters; design calculation of casting model was undertaken. Three case studies i.e. analysis based on the solidification method, were carried out for defect analysis of casting component and simulation study was done for process parameter optimization using ADSTEFAN software. It was observed that molten metal enters at critical location of cover plate causing turbulence in metal flow and solidification was not getting achieved in the directional way, thereby resulting in shrinkage defect. The shrinkage defect was removed by providing risers at proper location.

Application of Taguchi-based Six Sigma method to reduce defects in green sand casting process: a case study

2019 ◽  
Vol 13 (2) ◽  
pp. 226
Author(s):  
Vijaykumar Hiremath ◽  
Roopa B. Math ◽  
Mahantesh M. Ganganallimath ◽  
Suraj Dhondiram Patil ◽  
E.V. Gijo
Keyword(s):  
Six Sigma ◽  
Casting Process ◽  
Sand Casting ◽  
Green Sand

Pengukuran Kinerja Supply Chain Menggunakan Supply Chain Operation Reference (Scor®) (Studi Kasus Koperasi Baitul Qiradh Baburrayyan)

2019 ◽  
Vol 2 (2) ◽  
Author(s):  
Raysa Aleyzia ◽  
Hasan Yudie Sastra
Keyword(s):  
Supply Chain ◽  
Supply Chain Management ◽  
Six Sigma ◽  
Green Beans ◽  
Chain Management ◽  
Total Cost ◽  
Target Value ◽  
Chain Operation ◽  
Cost To Serve ◽  
Supply Chain Operation

Manajemen supply chain yang tidak maksimal akan mempengaruhi kinerja suatu perusahaan. Di Aceh Tengah terdapat suatu koperasi yaitu Koperasi Baitul Qiradh (KBQ) Baburrayyan yang sudah menerapkan manajemen supply chain. Koperasi ini bergerak di bisnis perdagangan biji kopi (green bean). Penelitian ini bertujuan untuk mengukur kinerja supply chain dari KBQ Baburrayyan. Metode yang digunakan adalah SCOR® dengan praktik perbaikan Convergence of SCOR® with Lean and Six Sigma. Target kinerja yang diperoleh untuk total cost to serve adalah sebesar 94,71% dari nilai target 65,00% dan untuk return on supply chain fixed asset adalah sebesar 1,60 dari nilai target 2,50. Hasil yang diperoleh dari penggunaan praktik tersebut adalah terdapat 8 akar penyebab waste di antaranya kurangnya tenaga pengawas, training/briefing belum maksimal, kurangnya kepedulian tentang pentingnya K3, layout yang kurang efisien, belum adanya unit penyuluhan, alat yang masih sederhana, pekerjaan yang monoton, dan tidak dilarang secara tegas.   Supply chain management that is not optimal will affect the performance of a company. In Central Aceh there is a cooperative namely Koperasi Baitul Qiradh (KBQ) Baburrayyan which has implemented supply chain management. This cooperative is engaged in the business of trading in green beans. This study aims to measure the supply chain performance of KBQ Baburrayyan. The method used is SCOR® with the practice of improving Convergence of SCOR® with Lean and Six Sigma. The performance target for total cost to serve is 94.71% of the target value of 65.00% and the return on supply chain fixed assets is 1.60 of the target value of 2.50. The results obtained from the use of the practice are that there are 8 root causes of waste including lack of supervisors, training / briefing is not maximal, lack of concern about the importance of K3, inefficient layouts, absence of extension units, simple tools, monotonous work, and not strictly prohibited.

Doskonalenie organizacji poprzez wdrażanie koncepcji Six Sigma

2008 ◽  
pp. 39-42
Author(s):  
Maciej Urbaniak
Keyword(s):  
Six Sigma

Celem artykułu jest przedstawienie metodyk (DMAIC/DMADV) odnoszących się do doskonalenia procesów i produktów, określanych jako Six Sigma. Istotną rolę we wdrażaniu projektów usprawnień poprzez wykorzystanie tych metodyk odgrywają kwalifikacje pracowników. Organizacje wykorzystujące Six Sigma jako narzędzie doskonalenia operacyjnego starają się aktywnie włączać w realizację tych projektu wszystkich pracowników. Powinni oni przejść cykl intensywnych szkoleń, podczas których nabywają umiejętności niezbędnej do posługiwania się narzędziami i technikami mogącymi mieć zastosowanie w implementowanych usprawnieniach.

Concept of Six Sigma and its Application in Banking

2011 ◽  
Vol 3 (7) ◽  
pp. 433-436 ◽  
Author(s):  
ADITI SHARMA ◽  
◽  
Dr. SUDHINDER SINGH CHOWHAN
Keyword(s):  
Six Sigma
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