Utilization of Six Sigma Method to Reduce Defects in Green Sand Casting Process and Improve the Productivity

Six Sigma is statistical and scientific methods used to improve business profitability, efficiency and improved quality rate. The Six Sigma approach has been increasingly adopted worldwide in the manufacturing sector in order to enhance productivity and quality performance and to make the process robust to quality variations. In the present research work Six Sigma methodology is used for the part: Transmission Case. DMAIC (Define-Measure-Analyse-Improve-Control) methodology is used to minimize the defects in the Transmission Case. Project charter, process map and cause-and-effect diagram are the major tools used in this work. Design of experiments (DOE) and analysis of variance (ANOVA) techniques are combined to analyse the correlation of defects with the mould hardness, green strength, and pouring rate to eliminate/reduce the defects. Taguchi analysis is used to statistically analyse the experimental results, which confirms better performance in production by process parameters taken.