Capability enhancement of a metal casting process in a small steel foundry through Six Sigma: a case study

Abstract

Six Sigma is a proven disciplined approach for improving measurable efficiency parameters for any organisation. In this case study, Overall Equipment Effectiveness (OEE) for a 0.5 Ton induction furnace, which is a metric for Total Productive Maintenance initiative, has been calculated. As this performance was below the expectation level and resulting into outsourcing of jobs at higher cost, the Six Sigma methodology for overall improvement of performance of the furnace and the steel foundry was taken up. This case study shows how Define, Measure, Analyse, Improve, and Control (DMAIC) methodology of Six Sigma has been applied for process improvement considering OEE as a parameter. A multi-functional team of five members was formed. The application of statistical data analysis was performed with the help of standard statistical software packages like MINITAB and STATISTICA. Successful implementation of this project has helped to turnaround the foundry and stopped drainage of capital through outsourcing after successful completion of the project.