Table 3 Use of new method to improve the process.
From: Enhancement in production efficiency using DMAIC methodology of six sigma
Defect | Identified the root cause problem | Method |
|---|---|---|
Pitting | The top and bottom die is not properly lubricated during working time | By training the oilman to lubricate the die after 3–4 pieces of manufacturing |
Die and billet are overheated during working time. | By maintaining a proper temperature range, depending on the product size | |
Reusing of used billet | Do not use more than two times a billet | |
Total length undersize | Use of more packing plate | Do not reuse more than three packing plates |
Less billet weight | Proper billet cutting by the cutting machine and weighing machines provided for efficient control | |
Not the proper function of the ejector system | By proper lubrication in the ejector system and by using a new ejector pin in the ejector system. Ejector pin is standardised depending upon the length of the product or by changing the ejector pin as per the preventive schedule | |
Un-filling defect | Die setting not proper | Use of a bolt and a clamp |
Low air pressure | By providing a pressure gauge in the machine | |
Undersize billet | Proper billet cutting by band saw machine and weighing machines to be provide better control. | |
Flash defect | Untimely change of die blocker | By changing the top blocker and bottom blocker after 6500–8500 pieces of manufacturing |
Material overlaps | By maintaining proper clearance between the top and bottom blocker dies and maintaining proper temperature | |
Die shortage | Maintain the single minute exchange die properly. | |
Bend defect | Unstandardised die punch | By using a new die or fewer than three packing plates |
Die loss during production | Die change by a preventive schedule. Top and bottom die change in 6500–8500 pieces of manufacturing |
