SIX SIGMA APPROACH FOR DETECTION AND REDUCING CASTING DEFECTS

Casting is a manufacturing process in which desired shape of a product is achieved by pouring liquid metal into a cavity having the pattern of the product called as mould and the product obtained is often called as casting. Casting companies faces various casting defects (blow, scab, drop, buckle, holes, misrun, rough surface) which leads to rejection of the product as it does not meet the customer acceptance specification and it results to financial loss. Six sigma a zero defect approach used in this paper to reduce casting defects and increase the efficiency of the production to meet the customer requirements. DMAIC (Define, Measurement, Analyze, Improve, and Control) a six sigma based methodology has been applied as the problem solving approach to reduce casting defects by controlling various parameters and processes. Use of six sigma (DMAIC) technique in reducing casting defects showed great results in terms of reduction of production wastes and thereby reducing the cost.