An experimental study based on Six Sigma approach to optimize chip formation in machining

Abstract

Quality and productivity have been distinguished as a significant role in any organization, especially for the manufacturing industry to gain more profit that prompts achievement of a company. In the manufacturing of pistons, the makers who are competing in the market want their products to be manufactured at less expense. In a large-scale manufacturing organization, which intends to produce around 600 to 800 parts per shift per line each and every single rejection record to the deficiency of Productivity. Defectives are investigated again and rework has to be done to bring down the number of damaged pistons, hence it reduces the quality of the product manufactured, devouring additional man and time. This paper reports a work improvement project in Federal-Mogul Goetze India limited. It involves Problem Identification in the production of pistons and proposing an effective framework to improve the current situation effectively. Based on the observation and data collection on day-to-day productivity, the major problem has been identified. To study and improve the problems identified methodology adopted is Six Sigma. DMAIC helps in understanding the process and the variables that affect it so that can be optimized the processes. The main objective of this case study is to reduce the number of defective pistons produced in the Piston Machine Shop. The outcome of this study is a suggestion to improve the process efficiency by parameter optimization that identifies and determines the root cause and controls the factors leading to desired output by following six sigma approaches.