Reduction in Rework of an Engine Step Bore Depth Variation using DMAIC and Six Sigma approach : A case study of Engine Manufacturing Industry

1. PVPIT, Bavdhan, Pune (M.S.) India, +919922964996 2. PVPIT, Bavdhan, Pune (M.S.) India, +919049981873 3. PVPIT, Bavdhan, Pune (M.S.) India, +919545648483 4. PVPIT, Bavdhan, Pune (M.S.) India, +919822702897 5. PVPIT, Bavdhan, Pune (M.S.) India, +919545371506 Abstract: Six sigma is one of the simplest and most powerful methodology used worldwide for quality and process improvement. The methodology can be applied to find the critical causes of process variation. Six sigma along with DMAIC can be combined used to achieve improved results in industries. The paper reports a case study of an engine manufacturing industry. Variation in depth of an engine bore was observed with unknown reasons as the pattern of variation in size was different. By using Six Sigma , DMAIC and fault tree analysis the probable reasons for variation were listed and experimentation were carried out to understand the effect of the variation in parameters on process output. Data was collected for each of the DMAIC phases. As the quantum of rework was too high and machine could not be stopped for complete experimentation the FTA analysis was selected and it proved to be efficient. After successful implementation it was observed that the engine bore rework was reduced from 18 % per month to 2.2 % per month. The paper explains the process applied for the reduction of rework using DMAIC and FTA in detail.

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