OPTIMIZATION OF DEFECTS IN CASTING OF PISTON WITH THE USE OF “DMAIC” (DEFINE, MEASURE, ANALYZE, IMPROVE, CONTROL) METHODOLOGY

Abstract

The goal of this research is to employ the DMAIC (Define, Measure, Analyze, Improve, and Control) Six Sigma Approach to minimize defect rates and improve the sigma level of the sand-casting process. This study specifies a step-by-step guide based on the DMAIC Methodology, and its efficacy has been assessed via a case study that shows an overall decrease in defect rejection and an increase in the process' sigma level from 3.32 to 3.47. Employee Job Satisfaction Following Six Sigma Implementation was also investigated. A total of 60 workers responded to the survey, yielding an 83 percent response rate. The findings suggest that participants in Six Sigma saw improvements in the majority of job satisfaction indicators. This program's implications are discussed, as well as future study objectives. Through an experiment, the study discusses how to reduce casting flaws in foundries. The research looks at how six sigma DMAIC (Define-Measure-Analysis-Increase Control) methodology may be used in the automotive sector to reduce casting errors in the manufacturing of aluminum pistons, optimize process variables, and improve performance.