Six Sigma DMAIC - Methodology to Improve the Quality of Cylinder Liners by Reducing the Black Dot

This paper focused on the quality improvement of the major defect in cylinder liners which are manufactured by injection moulding process. The major defect which occurs on the part of cylinder liners is block dot; due to this the rejection rate per unit is more. To identify the current quality problem and to improve quality in the injection moulding operation, six sigma DMAIC Methodology is adopted. As it is known fact that in the present scenario six sigma plays vital role in quality improvement. In order to analyze the data some of Statistical Quality Control (SQC) tools are used such as pareto chart, histogram, cause and effect diagram and control chart. To reduce this major defect black dot on cylinder liners, the readily available method screw and barrel cleaning is recommended. It is observed that with this analysis, the rejection rate of cylinder liners is found to be considerably reduced. Thus it leads to increase productivity and in turn saves other related cost and time.