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DEFECT ANALYSIS ON CASTING BY SIX SIGMA - QC TECHNIQUES TO MINIMIZE THE DEFECTS AND IMPROVE THE PRODUCTIVITY IN OIL PUMP CASTING

Abstract

The quick ever-changing economic conditions like global competition, client demand for top quality product, product selection and reduced interval, declining margin of profit etc. had a significant impact on producing industries. Six sigma is statistical and scientific strategies to reduce the defect rates and achieve improved quality. A case study carried out for a casting producing business. the target of the study is to reduce blow hole rejections by a) Improved cooling system in die b) Separate cooling line for OCV hole core pin c) Parameter setting changes d) Implementation of squeeze system to reduce internal porosity. Six sigma methodologies are used for the part in oil pump Casting. The key tools employed in this work are the project charter, process map and cause-andeffect diagram. To determine mathematically the correlation of defects with the mould hardness, green strength, and pouring rate additionally to seek out their optimum values needed to reduce or eliminate the defects. The experimental results were statistically analyzed and modelled through Taguchi analysis. based on the findings, improved cooling system in die. Separate cooling line for OCV hole core pin, Parameter setting changes, Implementation of squeeze system to reduce internal porosity. The optimized method parameters are taken for experiment and better performance obtained in the production process was confirmed. The comparison between the existing and the projected method has been tried during this paper and also the results are mentioned thoroughly.

SUNDAR SINGH SIVAM S.P1*, .SARAVANAN, N. PRADEEP, S.RAJENDRAKUMAR, AND K. SATHIYAMOORTHY

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