Culminating Project Title
Date of Award
Culminating Project Type
Mechanical and Manufacturing Engineering
College of Science and Engineering
Dr. Ben R. Baliga
Dr. Hiral A. Shah
Prof. Balasubramanian Kasi
Creative Commons License
This work is licensed under a Creative Commons Attribution-Noncommercial-No Derivative Works 4.0 License.
Keywords and Subject Headings
Induction Furnace, Foundry, Melting Process, Core sand
The purpose of this project is to demonstrate the application of Six Sigma tools for identifying and improving high overtime labor cost, poor process output and increased production wastes in a local foundry company. This study examines the process variations that lead to high production delays in the Molding Department and poor melt furnace output and increased slag forming in the Melt Departments. The project adopted Six Sigma Define-Measure-Analyze-Improve-Control methodology to improve the processes in both departments to reduce overtime labor cost and high production wastes. After completing the Define-Measure-Analyze phases, the team identified the root causes of high production delays in the Molding Department to be poor scheduling method. Meanwhile, the poor melt furnace output was caused by high runner hang-up delay, sand shakeout issues, material contamination, and equipment calibration issue. In addition, the increased slag formation was caused by raw sand, binder, mold design and sand shakeout issues. These problems were all addressed in the Improve-Control phases and satisfactory results were achieved by the team.
Fong, Chen Kwang, "Six Sigma–DMAIC Approach for Improving Induction Furnace Efficiency and Output at an Iron Foundry Plant" (2016). Culminating Projects in Mechanical and Manufacturing Engineering. 53.