Ambience of Six Sigma in

Indian foundries – an
empirical investigation
HIGH MATERIAL REJECTION
IN MALDEN M/C SHOP

By
Dr. Bikram Jit Singh
Professor
MMDU Mullana
BUSINESS CASE

• BACKGROUND: PISTON MANUFACTURING FOR

EXPORT.
• MATERIAL REJECTION IN MALDEN M/C SHOP IS
15.5% Avg.FROM JAN.07 TO JUNE-07 (9.73 TO 33.92
%) RESULTING IN ADDITIONAL COST, LOSS OF
PRODUCTION AND CAN DELAY IN DELIVERY
OBJECTIVE

• TO REDUCE THE MATERIAL REJECTION IN FM-132

ALLOY FROM MAY-31.8 & JUNE-31.5 % TO 16.0%

• TARGET DATE IS DEC.-07

• ACHIEVED IN DEC.-07 - 12.0 %

SCOPE AND BOUNDRIES

• ALL PISTONS CAST FROM FM -132 ALLOY.

• BY IMPROVING THE PROCESS STARTING FROM

MELTING AND ENDING AT CASTING.
SCHEDULE
DEFINE PROBLEM 16.08.07

OBSERVATION 25.08.07

ANALYSIS 15.09.07

ACTION 16.09.07

CHECK 30.09.07

STANDARDIZATION 15.10.07

CONCLUSION 15.11.07
TEAM MEMBERS
N.S.BAWA CHAMPION

R.K SHARMA TEAM LEADER(QUALITY)

R.SOOD MEMBER(PRODUCTION)

Y.DHIR MEMBER(MELTING)

B.MATTU MEMBER (PRODUCTION)

H WALIA MEMBER (PRODUCTION)

M.HAYAT MEMBER (PRODUCTION )

RESOURCES REQUIRED

• THE PROJECT WILL BE HANDLED WITH EXISTING

FACILITIES & RESOURCES AVAILABLE.
REJECTION
FOUNDRY IN MACHINE SHOP (MALDEN)
33.92
35

30

25
20.63
20
%AGE

15.18 15.2
12.52 12.81
15 11.42
10 9.73 11.75

10 8.5
8 6.7

0
TAR.07 JAN07' FEB07' MAR07' APR07' MAY07' JUNE07' JLUY07' AUG07' SEP07' O CT07' NO V07' DEC07'

MONTH
RECENT SCRAP HISTORY FOUNDRY IN M/C
SHOP

9 8.1
8 7.2 7.1 7.2
6.9 6.6
7

5
%AGE

0
JAN08' FEB08' MAR08' APR08' MAY08' JUN08

MONTH
ALLOYWISE REJECTION (MALDEN)
REJECTION
ALLOY WISE MATERIAL REJECTION IN MACHINE SHOP FOR MALDEN

FM132 HYPER FORGE TOTAL

35 31.8 31.5

30

25
20.6

20
%AGE

13.2 15.2 14

15

10

0.4 0.7
5

0
May-07 Jun-07
MONTH
 REJECTION PARETO
PARETO CHART BY DEFECT TYPES IN MAY07 ALLOY FM132 PARETO CHART BY DEFECT TYPES IN JUNE07 ALLOY FM132
TOTAL TOTAL
INSPECTED 8504 P= POROSITY 1=BOTTOM INSPECTED 39414 P= POROSITY 1=BOTTOM
GOOD 3896 S=INCLUSION/ SHRINKAGE
2=RING ZONE GOOD 20233 S=INCLUSION/ SHRINKAGE
2=RING ZONE
MATERIAL MATERIAL
SCRAP 2709 B= BLOW HOLE 3=SKIRT SCRAP 12420 B= BLOW HOLE 3=SKIRT
SCRAP% 31.86% C=CRACK 4=PIN HOLE SCRAP% 31.51% C=CRACK 4=PIN HOLE
DEFECTS P B' S DB DEFECTS P S B DB C
NOS. 1630 392 375 312 NOS. 5014 3714 2139 1263 290
%AGE 60.2 74.6 88.5 100.0 %AGE 40.4 70.3 87.5 97.7 100.0
19.2% 4.6% 4.4% 3.7% 12.7% 9.4% 5.4% 3.2% 0.7%
NOS. NOS.
1800 %AGE 120.0 6000 %AGE 120.0
1630
1600 100.0 5014 97.7
100.0 5000 100.0
100.0
1400 88.5 87.5

1200 80.0 4000 3714 80.0

74.6
1000 70.3

60.2 60.0 3000 60.0

800
2139
600 40.0 2000 40.4 40.0

392 1263
400 375
312
20.0 1000 20.0
200
290

0 0.0 0 0.0
P B' S DB P S B DB C
 PROCESS FLOW CHART

COMPOSITION
MELTING CHECK METAL
R-R ALLOYING TREATMENT
LAB

APPROVAL
OF DENSITY
PREMELTING INDEX
INGOTING
CHIPS

CASTING
PROCESS MAPPING

INPUT PROCESS OUTPUT

MANPOWER MELTING & FLUXING METAL FOR CASTING

MATERIAL
INDUCTION
FURNACE.
ALLOY COMPOSITION
FLUXES
MEASURING INST
METHOD
 CAUSE AND EFFECT
DIAGRAM
METAL DIE APPLICATION
–FM132 ALLOY
Tapping Outer mould
Temperature relief
Composition
Water Air venting
Circulation
Casting Flow lines
Temperature

GAS POROSITY
ON SKIRT AND
CROWN

Degassing Skimming of
Treatment Crucible cleaning metal Good tool &
die paint

VAC Test
Pouring
For GAS Check Rabbling with flux
Hourly out put

METHOD OPERATOR
TRIALS

TRIALS CONDUCTED AT DIFERENT VAC TEST INDEX

PART N0.463
CASTING TEMP 690 -700 DEG C
PISTON GOOD MAT. SCRAP %AGE
VAC TEST TURNED
INDEX
0.6 29 23 6 20.6
0.5 35 31 4 11.4
0.4 28 25 3 10.7
0.3 34 31 3 8.8
0.2 30 27 3 10
0.1 36 34 3 8.3
0.0 30 28 3 10
TRIALS
TRIALS CONDUCTED AT DIFERENT CASTING TEMP.
PART NO. 463 ALLOY FM-132
DENSITY INDEX 0.3
PISTONS VISUALY MAT.SC MAT. %AGE
CASTING TURNED GOOD RAP SCRAP
TEMP.DEG. POROSI SHRINKA
C TY GE
735 100 26 62 12 74
720 48 21 15 2 35
710 40 32 7 1 20
700 40 37 3 - 7.5
690 36 33 3 - 8.3
680 43 37 3 3 13.9
670 40 37 3 - 7.5

BIGGER LOT

690-700 183 164 12 7 10.38

TRIALS
RESULTS OF A BATCH MADE FOR COMPARATIVE STUDY

PART NO. 381NP ALLOY FM -132

CELL NO. 5 HFC. NO. 9&10

DENSITY INDEX 0.2-0.3 CASTING TEMP. 690 -700 DEG. C.

PISTONS TURNEND 868

VISUALY GOOD 763

MAT.SCRAP 105

%AGE 12.09 ( 39.8 % for same Part no

made in May 07)
 REJECTION
MATERIAL REJECTION IN MACHINE SHOP FOR MALDEN FM132 ALLOY

35 31.8 31.5
30

22.2
*
25
21.9
20.8 17.6
20

12.8 12
15

10

0
May- 07 J un- 07 J ul- 07 Aug- 07 S ep- 07 Oc t- 07 Nov- 07 Dec - 07

MONTH

*INCLUDES PART NOS. 704, 31630/ 34807, 32639, 1080P AND 310NP MADE BEFORE JUNE07 AND ARE
HAVING 40% MATERIAL REJECTION. WITHOUT THESE IT IS 12%
RECENT REJECTION IN FM132 ALLOY

14 12.54
12.1
11.45
12
10.13
9.8 9.87
10

8
%AGE

0
JAN08' FEB08' MAR08' APR08' MAY08' JUN08

MONTH
CONCLUSION
FM132 ALLOY REJECTION STATUS
MONTH GOOD MATERIAL %AGE
REJECTION
MAY2007 3896 2709 31.8
JUNE2007 20233 12420 31.5
JULY2007 19456 7573 22.2
AUG2007 16910 6515 21.9
SEP2007 20866 7102 20.8
OCT2007 22114 4976 12.8
NOV2007 11492 3736 17.6
DEC2007 18176 3234 12.0

•ONE MAN DEPUTED IN EACH SHIFT FOR CONTROLLING THE CASTING TEMPEERATURE
AND CHECKING THE DENSITY INDEX (VAC TEST ) AT REGULAR INTERVALS.
•CONTROL PLAN CHANGED ACCORDINGLY.