Studies on six sigma implementation model to improve customer satisfaction in sand casting foundries

Abstract

Six Sigma has been widely adopted in a variety of industries as a newlineproven management innovation methodology to produce high-quality newlineproducts with the lowest possible cost. This research defines a step-by-step newlineguide, using the DMAIC (Define, Measure, Analyze, Improve, and Control) newlinemethodology. Also the effectiveness of the DMAIC has been evaluated with a newlinecase study carried out in a south Indian foundry. This methodology is used to newlineidentify hidden waste and costs, identify and eliminate defects, increase profit newlinemargins, increase the employee s level of commitment and satisfaction, ontime newlinedelivery and in turn to improve customer satisfaction. In this research, newlinethe prime focus is on improving customer satisfaction in the sand casting newlinefoundries. newlineThe empirical study on employee job satisfaction upon newlineimplementing Six Sigma is also studied. The results show that participants in newlineSix Sigma have experienced positive changes in most job satisfaction newlinemeasures. Implications of the evaluation investigated with direction for newlinefurther action of the company. Taguchi optimization technique for selected newlineprocess parameters of green sand casting is applied to obtain optimal level of newlinethe process parameters in order to generate the optimum quality newlinecharacteristics of the cast iron flywheel castings. The process parameters considered are moisture content, permeability, loss on ignition, newlinecompressive strength, volatile content, vent holes, pouring time, pouring newlinetemperature, and mould pressure. An orthogonal array, the signal-to-noise newline(S/N) ratio, and analysis of variance are used to analyze the effect of selected newlineprocess parameters and their levels on the casting defects. The result shows newlinethat the selected process parameters significantly affected the casting defects newlineand a confirmation run is used to verify the results. newline