Date of Award
8-2016
Culminating Project Type
Starred Paper
Degree Name
Engineering: M.E.M
Department
Mechanical and Manufacturing Engineering
College
College of Science and Engineering
First Advisor
Dr. Ben R. Baliga
Second Advisor
Dr. Hiral A. Shah
Third Advisor
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
Abstract
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.
Recommended Citation
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.
https://repository.stcloudstate.edu/mme_etds/53
Correction to table page error
Comments/Acknowledgements
I want to thank Dr. Baliga for acting as my advisor and committee chair. He has been a great professor and leader to the students of Master in Engineering Management (MEM) in St. Cloud State University. I would also like to thank Dr. Shah and Prof. Kasi for acting as my committee members. Dr. Shah has always provided great supports and advice to the MEM students. Whereas, Prof. Kasi has always volunteered to be a committee member for MEM students’ capstone project. Nevertheless, all faculties and students in the Department of Mechanical and Manufacturing are very grateful for the supports and services provided by Sue E. Pope. Without her, everyone’s experience with the department would not be the same. Finally, special thanks to my project team members and the managements in the local foundry plant for their supports in making this capstone project an unforgettable learning experience.