Purpose

The purpose of this paper is to illustrate how Six Sigma methodology has been applied in a small-scale foundry industry to improve the overall first-pass material yield and quality, with a view to the product and the process.

Design/methodology/approach

The researchers have reported this paper based on a case study carried out in industry using the Six Sigma Define, Measure, Analyze, Improve and Control (DMAIC) and its application in improving the manufacturing process of a foundry shop.

Findings

Identified root causes are validated and countermeasures are implemented for improvement. As a result of this case study, the overall first-pass yield of the sand casting process is improved to 78.88% from the previous yield of 67%. For product-specific case, yield is improved by 18% through the improved gating system design. Sigma level of the process is improved to 3.08 from baseline 2.21. Key lessons learned from this case study are mentioned in the current study.

Research limitations/implications

This case study provides a standard road map and motivates small-scale foundry industries to implement Six Sigma methodology for productivity improvement, especially in jobbing foundry. The presented paper is based on a single case study, and the results are limited to the company only. Also, one of the reasons for low process yield is slag creation, which is not covered here, as it is a concern of the material quality supplied by the vendor. However, the approach of this paper is generic for learning perspective.

Practical implications

This case study provides a standard road map and motivates small-scale foundry industries to implement Six Sigma methodology for productivity improvement, especially in jobbing foundry. Through the effective application of Six Sigma quality initiative, how a quantum jump in financial aspect could be gain, has been demonstrated.

Originality/value

This research study showcases step-by-step implementation of Six Sigma-DMAIC methodology at a small-scale foundry industry. This paper could serve as a unique roadmap for practitioners and academicians to improve the material productivity of the foundry industry both ways, product and process.

中文翻译：

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通过砂型铸造行业的 6 Sigma 竞争优势提高整体一次合格率：SSE 案例研究

目的

本文的目的是说明六西格码方法如何在小规模铸造行业中应用，以提高整体一次通过材料的产量和质量，从产品和工艺的角度来看。

设计/方法/方法

研究人员根据在工业中使用六西格码定义、测量、分析、改进和控制 (DMAIC) 进行的案例研究及其在改进铸造车间制造过程中的应用报告了这篇论文。

发现

确认已识别的根本原因并实施对策以进行改进。作为本案例研究的结果，砂型铸造工艺的整体一次合格率从之前的 67% 提高到 78.88%。对于特定产品的情况，通过改进的浇注系统设计将良率提高了 18%。过程的 Sigma 水平从基线 2.21 提高到 3.08。当前的研究中提到了从这个案例研究中吸取的主要经验教训。

研究限制/影响

本案例研究提供了标准路线图，并激励小规模铸造行业实施六西格码方法来提高生产力，尤其是在加工铸造中。所呈现的论文基于单个案例研究，结果仅限于公司。此外，工艺产量低的原因之一是炉渣的产生，此处未涵盖，因为这是供应商提供的材料质量的问题。然而，本文的方法对于学习的观点是通用的。

实际影响

本案例研究提供了标准路线图，并激励小规模铸造行业实施六西格码方法来提高生产力，尤其是在加工铸造中。通过六西格码质量计划的有效应用，已经证明了如何在财务方面获得巨大的飞跃。

原创性/价值

本研究展示了在小型铸造行业中逐步实施 6 Sigma-DMAIC 方法。本文可为从业者和院士提供独特的路线图，以提高铸造行业产品和工艺的材料生产率。