Taguchi-Based Six Sigma Defect Reduction of Green Sand Casting Process: An Industrial Case Study

In recent years, Six Sigma has become one of the most popular quality control methodologies, enabling many companies to make measurable increases in quality and decreases in variation and defects. This article applies the concept of Six Sigma define-measure-analyze-improve-control (DMAIC) methods to a metal casting industry to systematically identify and solve the major problems faced by the company that uses the green sand casting process. DMAIC phases are used to decrease the defect rate from 31% (baseline) to 4%. A casting industry case study was demonstrated step by step, systematically using Six Sigma in this article.

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