Scrap Reduction in a Piston Manufacturing Industry

Scrap Reduction in a Piston Manufacturing Industry
Author: Dhiraj Kumar
Publisher:
Total Pages:
Release: 2015
Genre:
ISBN:
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Six Sigma at many organizations simply means a measure of quality that strives for near perfection. It is a disciplined data-driven approach and methodology for eliminating defects in any process, from manufacturing to transaction and from product to service. This paper demonstrates the empirical application of Six Sigma and DMAIC to reduce product scrap within a piston manufacturing organization. The paper follows the DMAIC methodology to investigate defects and root causes, and provides a solution to reduce/eliminate these defects. The analysis employing Six Sigma and DMAIC indicates that the design of casting spoon and its material influence the amount of defective pistons produced. In particular, the why-why analysis and two sample t-Test are combined to statistically determine the correlation of the casting spoon design and its material with defects as well as to define their optimum values needed to reduce/eliminate the defects. As a result, a reduction of scrap percentage from 9.9% to 5% was achieved, which helped the studied organization to reduce its Defects Per Million Opportunities (DPMO) from 99,000 to 50,000 and thus improve its Sigma level from 2.86 to 3.2. Also, the process yield was improved from 90.1% to 95% and a saving of 52 lakh/year was obtained.

Advances in Industrial and Production Engineering

Advances in Industrial and Production Engineering
Author: Rakesh Kumar Phanden
Publisher: Springer Nature
Total Pages: 976
Release: 2021-03-21
Genre: Technology & Engineering
ISBN: 9813343206
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This book comprises the select proceedings of the 2nd International Conference on Future Learning Aspects of Mechanical Engineering (FLAME) 2020. In particular, this volume discusses different topics of industrial and production engineering such as sustainable manufacturing processes, logistics, Industry 4.0 practices, circular economy, lean six sigma, agile manufacturing, additive manufacturing, IoT and Big Data in manufacturing, 3D printing, simulation, manufacturing management and automation, surface roughness, multi-objective optimization and modelling for production processes, developments in casting, welding, machining, and machine tools. The contents of this book will be useful for researchers as well as industry professionals.

Proceedings of the 6th Brazilian Technology Symposium (BTSym’20)

Proceedings of the 6th Brazilian Technology Symposium (BTSym’20)
Author: Yuzo Iano
Publisher: Springer Nature
Total Pages: 1030
Release: 2021-06-14
Genre: Technology & Engineering
ISBN: 3030756807
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This book presents the Proceedings of The 6th Brazilian Technology Symposium (BTSym'20). The book discusses the current technological issues on Systems Engineering, Mathematics and Physical Sciences, such as the Transmission Line, Protein-Modified Mortars, Electromagnetic Properties, Clock Domains, Chebyshev Polynomials, Satellite Control Systems, Hough Transform, Watershed Transform, Blood Smear Images, Toxoplasma Gondi, Operation System Developments, MIMO Systems, Geothermal-Photovoltaic Energy Systems, Mineral Flotation Application, CMOS Techniques, Frameworks Developments, Physiological Parameters Applications, Brain–Computer Interface, Artificial Neural Networks, Computational Vision, Security Applications, FPGA Applications, IoT, Residential Automation, Data Acquisition, Industry 4.0, Cyber-Physical Systems, Digital Image Processing, Patters Recognition, Machine Learning, Photocatalytic Process, Physical–Chemical Analysis, Smoothing Filters, Frequency Synthesizers, Voltage-Controlled Ring Oscillator, Difference Amplifier, Photocatalysis, Photodegradation, current technological issues on Human, Smart and Sustainable Future of Cities, such as the Digital Transformation, Data Science, Hydrothermal Dispatch, Project Knowledge Transfer, Immunization Programs, Efficiency and Predictive Methods, PMBOK Applications, Logistics Process, IoT, Data Acquisition, Industry 4.0, Cyber-Physical Systems, Fingerspelling Recognition, Cognitive Ergonomics, Ecosystem Services, Environmental, Ecosystem Services Valuation, Solid Waste and University Extension.

Lean Six Sigma for Optimal System Performance in Manufacturing and Service Organizations: Emerging Research and Opportunities

Lean Six Sigma for Optimal System Performance in Manufacturing and Service Organizations: Emerging Research and Opportunities
Author: Tetteh, Edem G.
Publisher: IGI Global
Total Pages: 198
Release: 2018-02-09
Genre: Business & Economics
ISBN: 1522540636
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Businesses utilize various managerial processes focused on reducing waste, errors, and variability in products to maintain and improve business quality. By keeping a clean workspace and organized workforce, business processes aim for an efficient, continuous flow of production while still supporting iterative improvements in quality and output. Lean Six Sigma for Optimal System Performance in Manufacturing and Service Organizations: Emerging Research and Opportunities provides upcoming research on the strategies to improve processes in business while using Lean Six Sigma principals and applications. Featuring coverage on a broad range of topics, such as direct model technology, performance rework, and quality management methods, this book is geared towards professionals, academicians, students, and researchers interested in detailed research on recent advancements in the management of risk in all fields.

Disruptive Technology: Concepts, Methodologies, Tools, and Applications

Disruptive Technology: Concepts, Methodologies, Tools, and Applications
Author: Management Association, Information Resources
Publisher: IGI Global
Total Pages: 2186
Release: 2019-07-05
Genre: Business & Economics
ISBN: 1522592741
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The proliferation of entrepreneurship, technological and business innovations, emerging social trends and lifestyles, employment patterns, and other developments in the global context involve creative destruction that transcends geographic and political boundaries and economic sectors and industries. This creates a need for an interdisciplinary exploration of disruptive technologies, their impacts, and their implications for various stakeholders widely ranging from government agencies to major corporations to consumer groups and individuals. Disruptive Technology: Concepts, Methodologies, Tools, and Applications is a vital reference source that examines innovation, imitation, and creative destruction as critical factors and agents of socio-economic growth and progress in the context of emerging challenges and opportunities for business development and strategic advantage. Highlighting a range of topics such as IT innovation, business strategy, and sustainability, this multi-volume book is ideally designed for entrepreneurs, business executives, business professionals, academicians, and researchers interested in strategic decision making using innovations and competitiveness.

Global Practices in Knowledge Management for Societal and Organizational Development

Global Practices in Knowledge Management for Societal and Organizational Development
Author: Baporikar, Neeta
Publisher: IGI Global
Total Pages: 501
Release: 2017-11-03
Genre: Business & Economics
ISBN: 152253010X
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As entrepreneurs seek to gain an advantage against their competitors, understanding how to share information throughout their organization will be vital in their success. Accordingly, it is critical for researchers, managers, and consultants to strengthen their own systems to facilitate knowledge management and implement strategies that will launch them into the future. Global Practices in Knowledge Management for Societal and Organizational Development is an integral reference volume featuring leading academic research on the management and creation of knowledge and organizational development theories and models. Including coverage on a variety of related perspectives and subjects, such as infrastructure and services for knowledge organizations, ethics and the impact on knowledge management, and the future of knowledge workers, this book is an ideal reference source for organizational development specialists, consultants, policy makers, researchers, and graduate business students looking for advanced research on cultural aspects of knowledge management and creativity, innovation, and technology in learning communities.

WRAP THE SCRAP WITH DMAIC: Strategic Deployment of Six Sigma in Indian Foundry SMEs

WRAP THE SCRAP WITH DMAIC: Strategic Deployment of Six Sigma in Indian Foundry SMEs
Author: Kjit Bikram Singh
Publisher: Anchor Academic Publishing (aap_verlag)
Total Pages: 213
Release: 2015-06
Genre: Technology & Engineering
ISBN: 3954893959
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Six Sigma approach is generally employed to improve the sigma level of manufacturing or service processes by reducing their deviations and defects. Six Sigma provides the opportunity to eliminate mistakes, improve morale and save money. Doing things right in first time and keeping them consistent is the only idea behind Six Sigma. Its fundamental objective is to achieve customer satisfaction with continuous improvement in quality and productivity. Mostly we are emphasizing on various tools or techniques being used during DMAIC projects and almost ignore the procedure to execute different phases of the Six Sigma project. This book provides unique step by step methodologies to perform Define, Measure, Analyse, Improve and Control phases of a Six Sigma project, respectively. An empirical investigation has been carried out in a make-to-order type (medium sized) foundry and Six Sigma is successfully implemented by decreasing the scrap of piston castings, appreciably. The book focuses on scrap reduction specifically in Indian foundries and tries to find out the reasons of low productivity index. It also tends to shatter the various phobias of SMEs in context of Six Sigma by validating the compatibility of proposed methodologies through a successful case study in Indian foundry environments.