Status of Six Sigma and Other Quality Initiatives in Foundries Across the Globe

Abstract

Foundries are actively involved to reduce the scrap rejection and rework during the manufacturing process of the components and improving their sigma level. In 2014, global casting production in foundries are increased to more than 105 million metric tons, an increase of 2.3%, according to this year's MODERN CASTING Census of World Casting Production. This all papers discus various tools and techniques used in various phases of DMAIC like a ANOVA, process map, the cause effect matrix diagram, statistical methods, SQC, design of experiments (DoE) and Taguchi methods Fuzzy Analytic Hierarchy Process(FAHP) Total Productive Maintenance (TPM) which used by various foundries of world to enhance their manufacturing performance. Defect reduction is therefore chosen as the Critical-to- Quality (CTQ) factor, for world class quality in foundry products. Analysis is carried out using various software like Minitab, SPSS, and SPC for Excel etc. Study shows Six Sigma is a well-structured methodology to achieve expected goal which is need of the day in globally competitive era.