The Repository @ St. Cloud State

Open Access Knowledge and Scholarship

Date of Award


Culminating Project Type

Starred Paper

Degree Name

Engineering: M.E.M


Mechanical and Manufacturing Engineering


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

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.


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.

Chen Swang Fong - Six Sigma - Final Report.docx (4416 kB)
Correction to table page error



To view the content in your browser, please download Adobe Reader or, alternately,
you may Download the file to your hard drive.

NOTE: The latest versions of Adobe Reader do not support viewing PDF files within Firefox on Mac OS and if you are using a modern (Intel) Mac, there is no official plugin for viewing PDF files within the browser window.