A Six Sigma Methodology for Reducing Casting Defects in Foundry Operations

By Prem Saran Satsangi, Sushil Kumar and D.R. Prajapati.

Published by The Technology Collection

Format Price
Article: Print $US10.00
Article: Electronic $US5.00

Six Sigma is an organized and systematic method for strategic process improvement that relies upon statistical & scientific methods to make reductions in defect rates. A case study is carried out in casting industry, where Six Sigma tools i.e. Taguchi approach for the defect reduction is implemented. A set of process parameters that contribute various casting defects, are identified and analyzed. An orthogonal array, the signal to-noise (S/N) ratio and analysis of variance (ANOVA) criterion are used to analyze the effect of selected process parameters and their levels on the casting defects of the cast iron (grade-25) Differential Housing Cover castings. Optimized parameters are considered to build the empirical model for the differential housing castings. The experimental studies are carried out to validate the developed empirical expressions for casting defects with Multi Variable Linear Regression (MVLR) and Artificial Neural Network (ANN) methods.

Keywords: Six Sigma, Casting Defects, Regression Model, ANOVA

International Journal of Technology, Knowledge and Society, Volume 8, Issue 4, pp.163-176. Article: Print (Spiral Bound). Article: Electronic (PDF File; 926.308KB).

Prof. Prem Saran Satsangi

Associate Professor, Mechanical Engineering Department, PEC University of Technology, India

The author is working as an Associate Professor in the Department of Mechanical Engineering, PEC University of Technology (formerly Punjab Engineering College), Chandigarh, India. He has more than 25 years of experience working in PEC University of Technology as well as at National Teachers’ Training Institute, Chandigarh, India. He has published many research papers in international and national journals of repute and in the proceedings of the conferences. He has organised many training programmes both in technical areas as well as on design and preparation of audio–visual aids for effective instructions. He is also a reviewer of national and international journals. He guides research at postgraduate and doctoral level.

Sushil Kumar

Associate Professor, Mechanical Engineering Department, Indo-Global College of Engineering, India

Sushil Kumar is working as an Associate Professor in the Department of Mechanical Engineering, Indoglobal College of Engineering, Mohali, Punjab, India. He holds MTech from the Punjab University, Chandigarh, India and MBA from the Indira Gandhi National Open University, Delhi, India. He has published more than seven research papers in international and national journals of repute and in the proceedings of the national and international conferences. He has given so many expert lectures on different topics in the field of quality, defense sector and mechanical engineering. He has also worked for Indian Defense Service for 20 years as an Mechanical Engineer and served in different field.

D.R. Prajapati

Assistant Professor, Mechanical Engineering Department, PEC University of Technology, India


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