Abstract

The define–measure–analyze–improve–control (DMAIC) approach is a five-strata approach, namely DMAIC. This approach is the scientific approach for reducing the deviations and improving the capability levels of the manufacturing processes. The present work elaborates on DMAIC approach applied in reducing the process variations of the stub-end-hole boring operation of the manufacture of crankshaft. This statistical process control study starts with selection of the critical-to-quality (CTQ) characteristic in the define stratum. The next stratum constitutes the collection of dimensional measurement data of the CTQ characteristic identified. This is followed by the analysis and improvement strata where the various quality control tools like Ishikawa diagram, physical mechanism analysis, failure modes effects analysis and analysis of variance are applied. Finally, the process monitoring charts are deployed at the workplace for regular monitoring and control of the concerned CTQ characteristic. By adopting DMAIC approach, standard deviation is reduced from 0.003 to 0.002. The process potential capability index (CP) values improved from 1.29 to 2.02 and the process performance capability index (CPK) values improved from 0.32 to 1.45, respectively.

Highlights

  • An engine crankshaft forms the most dynamic and crucial part of an engine

  • The present work elaborates on DMAIC approach applied in reducing the process variations of the stub-end-hole boring operation of the manufacture of crankshaft

  • This is followed by the analysis and improvement strata where the various quality control tools like Ishikawa diagram, physical mechanism analysis, failure modes effects analysis and analysis of variance are applied

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Summary

Introduction

An engine crankshaft forms the most dynamic and crucial part of an engine. The manufacture of the crank shaft poses challenges as it involves as many as 23 critical to quality (CTQ) characteristics. One such CTQ characteristic is the stubend-hole diameter formed by boring operation. This machining operation is important because, after this operation the finishing line operations of crankshaft journals’ and pins’ grinding and lapping succeed. The stub-endhole boring operation is the last roughing line operation of the crank shaft and is a bottleneck operation This is the inspiration behind to select the stub-end-hole boring operation for process capability improvement study. Statistical process control (SPC) widely employs various process monitoring charts for determining whether the process under consideration is performing within the specified limits are not. CP gives a measure of the variation and deviation in the

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