Implementation of Six Sigma Methodology for Piston Rod Manufacturing

This research paper deals with a case study of Piston Rod. Rejection of Piston Rod was the main problem in company due to defects of pitting; porosity etc. DMAIC approach (Six Sigma Methodology) was used to reduce the defects and increase the productivity. Plasma Nit riding of AISI 4140 Alloy Steel was carried out at plasma nitration technology. The effect of temperature on the surface hardness and microstructure was investigated along with their corrosion resistance. The Plasma (Ion) Nit riding technology shows a clear orientation towards future developments. Hence, it ideally satisfies current and future industrial demands for economical and efficient solutions to the treatment of surfaces. It is also an answer to social demands for improved environmental protection. In the second phase the collected data was validated by collecting sampling during production hours, which helped in representing a true picture of defects, occurred after Plasma Nit riding. Finally an analysis was done using Six Sigma technique. Then, the cause and effect diagram was used to explore possible causes of defects through a brainstorming session and to determine the causes which had major effect. Some corrective measures are also suggested to overcome these defects. Six-Sigma, mainly based on customer needs & expectation with the use of facts & statistics, analysis & responsible approach to managing & improving current business, manufacturing capacity & services is applicable to such cases. Tools of six sigma methodology are used to improve the process by enhancing the quality of product. This paper draws attention towards adoption of six sigma methodology in manufacturing organization with the case study. This is successfully achieved by implementing DMAIC Methodology. Citation: Yogesh Sanjay Khawale, NBN Sinhgad School of Engineering, Ambegaon; Sanjog Chandrakant Jagdale ,NBN Sinhgad School of Engineering, Ambegaon; Sanat Sanjay Jambhalekar ,NBN Sinhgad School of Engineering, Ambegaon; Suraj Shreeram Kale ,NBN Sinhgad School of Engineering, Ambegaon; Prof.V.H.Patil ,NBN Sinhgad School of Engineering, Ambegaon. "Implementation of Six Sigma Methodology for Piston Rod Manufacturing." Global Research and Development Journal For Engineering 23 2017: 14 - 18.