Defect control analysis for improving quality and productivity: an innovative Six Sigma case study

摘要

This research study proposes an innovative analysis for controlling the defects in aluminium die casting industry. In this analysis, casting process of a two-stroke engine oil pump body is concentrated. The component selected has often rejected due to blow hole defects. Six Sigma, the zero defect approach, is used in this study. Define measure, analyse, improve and control (DMAIC) problem solving methodology is applied for problem analysis. Taguchi's experimental design is used for process validation and improvement. The confirmation experiment showed that the rejection rate was reduced to 4.8% from 17.22%. The application of Six Sigma program with Taguchi technique has developed an innovative cost effective methodology for controlling defects in die casting process in less experimental time.