Enhancing Effectiveness of Shell and Tube Heat Exchanger through Six Sigma DMAIC Phases

Abstract This research portrays the pilot implementation of Six Sigma DMAIC (Define-Measure-Analyze-Improve-Control) phases to improve the effectiveness of shell and tube heat exchanger in a small sized furnace manufacturing company. Shell and tube heat exchanger is one of the critical components of the furnace. The imperative objective is to improve the quality of the furnace through DMAIC phases. In define phase, the critical to quality (CTQ) parameter was identified as effectiveness in shell and tube heat exchanger through the voice of the customer (VOC) and Pareto Chart. In measure phase, the present effectiveness was measured as 0.61. In analysis phase, the reason for the reduction of effectiveness was identified as less heat transfer area through cause and effect diagram. In improve phase, the existing design was modified through various alternative solutions by conducting brainstorming sessions. In this phase, the solution was identified with the introduction of circular fins over the bare tubes to improve the effectiveness in the shell and tube heat exchanger. Consequently, the effectiveness has been enhanced from 0.61 to 0.664. In control phase, the control strategies were recommended to sustain the improvements in shell and tube heat exchanger. In the end, the annual monetary savings of Rs.0.34 million were achieved through the implementation of DMAIC phases in the furnace manufacturing company.