The present paper deals with the reduction of rejection due to casting defects in a foundry industry. The industry is making cast iron castings of submersible pumps components such as Upper housing, Motor Pulley, Mini Chaff cutter wheel in large scale and having rejection in the form of Misrun. The three important part of industry were chosen for complete analysis. The improvement in these defects can be done by the application of DMAIC approach. The study was done at HARYANA(India) on application of Six Sigma methodology and Selection of tools and techniques for problem solving, because of its high rejection rate. The results achieved show that the rejection due to sand casting defects has been reduced from 16.96% to 5.99% which saved the cost of Rs. 13339/-monthly(for continuous four months), in a turnover of 45 lakhs.
Reduction, Defects, Casting, Housing, Mini Chaff, Misrun, Motor pulley
