Dmaic Methodology for Reducing the Failure of Molds in Foundry Shop - A Case Study

Resumen

Today all industries facing the global competition. To overcome this foundries performance
should be high because they are important of part of manufacturing industries. Nowadays
many industries have adopted the DMAIC methodology for proper standing in market to face
the current scenario of global competition. DMAIC approach is best strategy for improving
the efficiency of all processes to meet customer’s needs. It is one of six sigma methodologies
which is used to improve quality by reduction of defects with the help of various tools and
techniques. Actually it is management approach which is applicable to all fields. In
present work, DMAIC methodology of six sigma used as defect reduction technique to
reduce casting defects for producing defect free molds in foundry. For this various types of
defects are identified, their various root causes and various ways for reducing the defects
according to phases of DMAIC. Present study was done through application of DMAIC
methodology with the help of various tools and techniques because of high rejection rate of
molds. This present work carried out in foundry to minimize the percentage rate of failure of
molds (due to various casting defects) in HNGIL(Hindustan National Glass & Industries
Ltd.), Bahadurgarh. In this paper, DMAIC methodology applied to foundry for reducing the
casting defects to obtain defect free molds in foundry. As a result, molds’ rejection rate
decreased from 26.8% to 19.88%.