Quality Improvement in the Cylinder Head of Petrol Engine by Implementation of DMAIC

The core objective of this project is to improve the quality along with the production capacity of the industry. In a machine shop, we all know that Cleaning machines are employed in each production line to ensure proper cleaning takes place after different operations (such as drilling, milling). The main purpose of this machine is to remove the metal chips produced during machining (i.e. reducing the amount of metal chips present). Instead the amount of metal chips present in the valve seat areas & rest of the areas of cylinder head exceeds their limit value. So a detailed study was carried out on the machine and its parts in order to understand the process thoroughly.

In order to meet the demand one of the lean manufacturing tools DMAIC (Define, Measure, Analyze, Improve and Control phase) has been implemented successfully. In the measure phase, the impurity trend of cylinder head was measured and analyzed using box plot. In the analyze phase, root cause analysis was performed so as to find the factors responsible for the increase in amount of metal chips present even after cleaning is done. The factors that contribute more for the inclusion of metal chip were identified through Pareto chart analysis and were given priority to make changes immediately. In the improve phase, design changes such as introduction of bracket & baffle plate in the overflow area was implemented so as to reduce the amount of metal chips present. In the control phase, control charts were plotted to monitor the improvements to ensure continued and sustainable success. Thus, resulting in the improvement of quality and overall productivity which helps the industry in meeting the demand.