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Molding A Solution Six Sigma
Molding A Solution Six Sigma
Molding a Solution
How Six Sigma
enhanced
product
performance
at an indian
foundry
By Prasun Das,
Indian Statistical
Institute, and
Abhranil Gupta,
Auctus Solutions
erformance measures how well a product functions for its intended uses. If a
product has multiple independent functions, its performance can be defined
as performance of the interacting chunks or modules of the product.1
The performance of the individual chunks or modules, in turn, depends on
the properties of the individual modules intended at the time of design. While
manufacturing the product according to the design, the intended properties
should be embedded, or there can be a deviation of the intended properties.
This deviation of the properties will lead to a fall in the products performance
level. In turn, the overall product performance will deteriorate as a cascading
effect of the falling performances of the individual chunks.
To study this dilemma, we looked at a manufacturer and its casting process of
gear boxes used as parts of mechanical power transmission units, and we asked
how Six Sigma could be applied to improve product performance.
The design, standards and norms (or intended properties) were set by the
customer who needed the product free of defectssuch as blowholes, gas porosity, cracks, shrinkage, misrun, dimensional accuracy and chilled surfaceper the
standards in the quality plan.
The objective of this work was to improve product performance by reducing
the nonconformities of the manufactured product, thereby improving product
performance and ensuring the product adhered to the design and specifications.
The deviations in the process, if minimized and controlled, could lead to about
10-15% fewer defective parts shipped to the customer that wouldnt have been
typically caught by inspection.2 The deviations from the standards were found to
be the result of the process.
Six Sigma was used to contain the defects or noises in the process, thereby
improving performance. The process was mapped through root cause analysis
(RCA), and failure mode and effects analysis (FMEA) was carried out using
domain knowledge to identify the key process input variables responsible for
failures.
Control mechanisms, too, were devised to monitor these inputs and thus
reduce defects. After the defects were totally contained, the product manufactured more consistently met standards and norms that were set in the design
stage by the customer.
At the foundry
In the example, quality consciousness became top of mind with management at the
foundry because of increased competition. In any foundry, better quality means
more competitive pricing of its product through less rework and rejection. Note
that the casting process in a foundry is complex and involves diverse skills, different
qualities of ingredients and technology. As variation in any process is inevitable, a
high amount of variation makes it challenging to anticipate and manage results.
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Objective
Scope
Present status
desired outputs. This goal should motivate organizations to silence or at least quiet the noise in any process
and improve product performance to the highest possible levels.
The foundrys objective was to use Six Sigma to
reduce defects and nonconformity. To define the
scope of work (the projects boundary) and to keep
the studys objective on the right track, the following
principles were adopted to yield maximum results:
No metallurgical innovations would be performed.
No dilution or change in the design and standards, set by the customer, would be done.
Define, select, measure and improve on the
defects would only be done by the selected
team.
Management would periodically review the
progress of the DMAIC phases.
Any further changes in scope could only be made
through the proper channels and authority.
DMAIC at the foundry
Define phase: The purpose of this phase was to identify
the project scope, define its objective and map the core
process to quantify the extent of the problem in the
next phase. The selection process of this project is outlined in the project charter shown in Table 1. Figure
1 is a detailed process map of the foundry operations,
which shows the process along with identification of
critical process variables.
The following are definitions of terms used in the
analysis:
Defect: Any deviation of any characteristic from
the standard.
Defective unit: Any unit (casting item) that
doesnt conform to one or more of the standard
M o l d i n g a S o l u ti on
Keep ready
for pouring
Mold box
Dry
Takeout
pattern
To mold
area
Cut gates
Ram
Add
mold
sand
Pattern
Core box
Store
Inspection
Operation
25
Transportation
10
Delay
To Assemble
store
Start
Dry
Takeout
pattern
Issue
Cut gates
Ram
To
Weigh
cupola pig iron
Mix
Green
Pan
Reclaimed
Keep ready
for molding
Measure
out
proportion
Inspection
Felting
Shake out
Cool
Pouring
Check temperature
Dry mix
To
sand mix
Weigh
To
home
cupola return
Coal
To home return
Put in furnace
fire
Weigh
To
cupola scrap
Betonite
Water
Storage: Storage of in-process, raw material and finished product in the inventory.
Inspection: Points in the system where the inspection is carried out.
Operation: Functions carried out to transform the raw material to finished product.
Transportation: Transporting work in progress inventory from one work station to another.
Delay: Delay in the process for any reason, including no job, no material and absence of workers.
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Molding a S olutio n
120
360
100
300
80
240
60
180
40
120
20
60
Ga
s
Bl
po
ro
si
ty
Sh
rin
ka
ge
M
is
ru
n
Di
m
en
si
on
Cr
ac
ks
Ha
rd
m
et
al
ow
ho
le
Defects
Frequency
Blowhole
98
Gas porosity
83
Shrinkage
64
Misrun
50
Dimension
20
Crack
18
Hard metal
Number of defects
Number of castings in charge
7
340
1,838
Defect opportunity
12,866
26,426.24
Sigma level
3.44
Significance
Amount of
green sand
Amount of green sand, if incorrect, will make incorrect permeability in the mixed sand, which is a determining
factor for the formation of the blowholes gas porosity. Also, the consistency of the mold will not be satisfactory. The grain size of green sand is different than the reclaimed sand. Hence, an incorrect mixture of the
two will cause a difference in inter-grain size, which will inhibit the free flow of entrapped gas and cause
blowholes.
Amount of reclaimed
sand
Reducing binders and catalyst is possible in reclaimed sand. Also, better dimensional control of castings can
be made while reducing large variations in impurity levels and screen analysis. An incorrect mixture of the
two will cause a difference in inter-grain size, which will inhibit the free flow of trapped gas and cause blowholes.
Amount of additives
Bentonite is the additive for binding sand, the amount of which is the strength-determining factor for mold/
core. This will affect consistency and strength in the pattern during pouring of hot metal and also affect the
dimensionality of the finished products.
Amount of water
Too much will cause blowholes, and too little will deteriorate mold/core strength significantly after baking.
Amount of water is directly proportional to forming water vapor inside the mold when hot metal is poured.
This water vapor can get trapped and form gas porosity.
Sieve is used to filter out the oversized grains from the sand. This filtration depends on the size of the sieve.
Hence, size and age of the sieve becomes important. As the sieve ages, its dimensional features are affected. Incorrect size of sand grains results in an incorrect size of mould, which will affect the intergrain distance
and cause blowholes.
The determining factor for the right mix of ingredients. Less time in pan making will result in heterogeneous
mixing and, therefore, inferior mold of sand.
Pattern age
As the patterns age, the dimensionality of the patterns lose their actual values, and the tapering increases.
This causes the internal features to break off while the pattern is taken out after ramming.
Gating cross-section
Cross-section of the main entry of molten iron that is poured into the mold. While pouring, if the cross-section is not appropriate, the molten iron may not flow freely, causing defects such as shrinkage or misruns.
Any decrease or stoppage of the cupola fan will result in low temperature of the molten iron, which will result
in defects such as a misrun.
Temperature of
molten metal
The accurate control of liquid metal temperature is important in the continuous and large-scale production of
a wide variety of castings to reduce casting rejects and scrap.
Pouring time has an indirect relationship with temperature of the molten iron poured into the mold for casting. Lower pouring time will solidify the iron much faster and avoid the shrinkage defect.
Cooling time
One of the primary factors for casting. Shorter cooling time will chill the surface, which is not intended by the
customer.
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M o l d i n g a S o l u t i on
Incorrect gating
of mold
Incorrect amount
of phosphorous
Inaccurate study
of pattern
features
Gate crosssection wrong
Scrap proportion
not OK
Scrap inspection
defective
Incorrect
phosphorous
ratio
Shrinkage
Pattern old
Environment
temperature
Temperature
gradient
Wrong methoding
Poor pattern
design
Pattern
conditions bad
Improper
maintenance
Sand coverage
thickness in mold
Poor casting
design
Rate of cooling
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Molding a S olutio n
Current
prevention
Current
detection
Detection
RPN
N/A
N/A
90
Scrap proportion
not OK
N/A
N/A
105
Scrap inspection
defective
N/A
N/A
252
Poor casting
design
10
Poor methoding
N/A
N/A
80
Pattern
making
Poor casting
design
N/A
N/A
72
Pattern
making
Poor casting
design
Improper
maintenance
N/A
N/A
30
Revamp maintenance
department.
Severity
Occurrence
Potential causes
Inaccurate study of
features of pattern
Low fluidity
Charging
Low fluidity
Pattern
making
Potential
failure effect
Pattern
making
Incorrect
gating
Charging
Process
Recommended action
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M o l d i n g a S o l u t i on
Vital
defect
Action plan
Blowhole/
gas
porosity
Issue
Mix by volume
Final mixture
Shrinkage
Misrun
Activities
Process
Dry mixture
Core sand
Mold sand
Green sand
5 parts
4 parts
Reclaimed sand
5 parts
6 parts
part
1 part
4 parts
4 parts
Yellow clay
Bentonite
Mix by volume
Machine/
equipment
Time
Water
Pan-making machine.
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Moldin g a S o lu tion
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