Identification and Analysis of Cold Metal Defect in Ferrous Casting using TRIZ Integrated Six Sigma Approach

Casting is a process to produce products of complex shape and size which is very difficult to produce by other processes. The various areas in casting process are pattern making, molding, core making, melting, pouring, etc.., It is very difficult to produce defect free casting. There are many defects that affect the quality of casting. This paper represents the procedure to analyze and minimize the cold metal casting defect in Pump Mounting Flange of gray cast iron. The gating systems are not always responsible for the defect occurrence. Here an attempt is made to identify the reason for the cold metal defect using TRIZ integrated Six Sigma approach. The six-sigma (DMAIC) methodology is adopted to carry out the work. Using TRIZ (Theory of Inventive Problem Solving), a tool for inventive problem solving the worsening features and improving features are identified from the TRIZ contradiction matrix and quality tools an ideal final result is obtained. The quality tools such as histogram, cause-and-effect diagram are used in various phases of six-sigma methodology.