Quality and productivity improvement using Six Sigma and Taguchi methods

Abstract

This research study proposes an innovative analysis for controlling the defects in aluminium die casting business. Six Sigma DMAIC (define, measure, analyse, improve, control) methodology is used to analyse the problem. Process validation is done with Taguchi DOE and ANOVA analysis at 95% confidence showed that the metal temperature is the vital process parameter causing defects. Confirmation experiment at optimum process parameter level showed defect level reduced from 17.22% to 4.8%. Since aluminium die casting is one of the most widely used process for producing automobile components, this study provides a methodology for improving the die casting business excellence.