DMAICT: a road map to quick changeovers

Abstract

In today's world, every customer wants his whistles and bells on the product, so in the near future only those manufacturers that can give quick response to ever changing demands of the market would survive. FIAM (2001) highlights setup reduction policy as a key strategy to make overall production more economical and flexible. This paper deals with a study carried out in light alloy foundry on how DMAICT approach of Six Sigma concept has decreased the die changeover times effectively. Generally Six Sigma methodology is employed to improve the sigma level of manufacturing or service processes by reducing their deviations and defects, but this work has proved how it can also be used for achieving breakthroughs in setup time reduction, specifically in foundries. After defining the root problems, the tools like value stream mapping and man-machine charts are used to measure the criticality of setup downtime (Armstrong and Coyle, 1999). On the basis of fish-bone analysis, rescheduling and externalisation of setup activities have been performed. Industrial engineering tools like 5-s, poka-yoke and standardisation of procedures further declined the die changeover times positively under the flag of DMAICT methodology. Pareto charts are made to clearly compare and assess the present and proposed setup procedure in terms of time and money.