Lean-Six Sigma Case Study to Improve Productivity in a Manufacturing Industry
Journal Title: International Journal of engineering Research and Applications - Year 2017, Vol 7, Issue 9
Abstract
Industries are in a path of adopting new technologies, equipment, approach to improve productivity and profitability. The change in mind of the industries is due to the raising demand from the customer for a quality products or services at a low cost with reduced lead time, further it is free from defects. These factors push the industries to focus on their improvements. The intent of this research work is, to improve the quality in manufacturing sector by combination of Lean and Six sigma. This projects addresses the productivity improvement of an industry by reducing the rejections using Lean Six Sigma DMAIC approach. The rejection data of last six months of the industry has been studied for rejection rate and its effect on industry’s production. Based on statistical data potential components are chosen for analysis, causes that led to rejections are analysed with lean Six Sigma framework. Loss due to tool failure, modification of cutting parameters for reduced production lead time is one of the major problems that causes the frequent rejection of components. Increased feed rate and speed results in tool wear, further use of unstandardized parameters cause such failure although it decreases the cycle time. Various combinations of cutting parameters were analysed using Taguchi methodology to study the effect of DOC, spindle speed, feed rate, cutting force and nose angle on cycle time. After evaluating the results a framework for standard cutting parameters which results in reduced cycle time as well as tool wear is framed out to follow. Scatter plot analysis were carried out to examine the investigation which showed that wear increases with increase in feed and speed and Wear increases with increase in DOC. It can be noted that changing the speed from 450 to 400, feed from 0.2 to 0.15, and DOC from 1 to 0.75 we can reduce the 6.1% time required to complete a turning operation further tool life is improved to extent of 20.00%.
Authors and Affiliations
Dr. Shanmugaraja M, Tharoon T
Keywords
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