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Six Sigma–DMAIC Approach for Improving Induction Furnace Efficiency and Output at an Iron Foundry Plant Chen Kwang Fong

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Six Sigma–DMAIC Approach for Improving Induction Furnace Efficiency and Output at an Iron Foundry Plant Chen Kwang Fong St. Cloud State University theRepository at St. Cloud State Culminating Projects in Mechanical and Department of Mechanical and Manufacturing Manufacturing Engineering Engineering 8-2016 Six Sigma–DMAIC Approach for Improving Induction Furnace Efficiency and Output at an Iron Foundry Plant Chen Kwang Fong Follow this and additional works at: https://repository.stcloudstate.edu/mme_etds Recommended Citation Fong, Chen Kwang, "Six Sigma–DMAIC Approach for Improving Induction Furnace Efficiency and Output at an Iron Foundry Plant" (2016). Culminating Projects in Mechanical and Manufacturing Engineering. 53. https://repository.stcloudstate.edu/mme_etds/53 This Starred Paper is brought to you for free and open access by the Department of Mechanical and Manufacturing Engineering at theRepository at St. Cloud State. It has been accepted for inclusion in Culminating Projects in Mechanical and Manufacturing Engineering by an authorized administrator of theRepository at St. Cloud State. For more information, please contact [email protected]. Six Sigma–DMAIC Approach for Improving Induction Furnace Efficiency and Output at an Iron Foundry Plant by Chen Kwang Fong A Starred Paper Submitted to the Graduate Faculty of St. Cloud State University in Partial Fulfillment of the Requirements for the Degree Master of Engineering Management August, 2016 Starred Paper Committee: Ben R. Baliga, Chairperson Hiral A. Shah Balasubramanian Kasi 2 Abstract The purpose of this project is to demonstrate the application of Six Sigma tools for identifying and improving high overtime labor cost, poor process output and increased production wastes in a local foundry company. This study examines the process variations that lead to high production delays in the Molding Department and poor melt furnace output and increased slag forming in the Melt Departments. The project adopted Six Sigma Define-Measure-Analyze-Improve-Control methodology to improve the processes in both departments to reduce overtime labor cost and high production wastes. After completing the Define-Measure-Analyze phases, the team identified the root causes of high production delays in the Molding Department to be poor scheduling method. Meanwhile, the poor melt furnace output was caused by high runner hang-up delay, sand shakeout issues, material contamination, and equipment calibration issue. In addition, the increased slag formation was caused by raw sand, binder, mold design and sand shakeout issues. These problems were all addressed in the Improve-Control phases and satisfactory results were achieved by the team. 3 Table of Contents Page List of Tables ....................................................................................................... 5 List of Figures ...................................................................................................... 7 Chapter I. Introduction ............................................................................................... 9 Introduction ......................................................................................... 9 Problem Statement ............................................................................. 9 Nature and Significance of the Problem .............................................. 9 Objective, Scopes and Deliverables of the Project ............................. 10 Project Questions/Hypotheses ............................................................ 11 Limitations of the Project ..................................................................... 11 Definition of Terms .............................................................................. 12 Summary ............................................................................................. 14 II. Background and Review of Literature ...................................................... 15 Introduction ......................................................................................... 15 Background Related to the Problem ................................................... 15 Literature Related to the Problem ....................................................... 19 Literature Related to the Methodology ................................................ 22 Summary ............................................................................................. 23 III. Methodology ............................................................................................. 24 Introduction ......................................................................................... 24 4 Chapter Page Design of the Study ............................................................................. 24 Data Collection .................................................................................... 26 Data Analysis ...................................................................................... 27 Budget ................................................................................................. 28 Summary ............................................................................................. 28 IV. Data Presentation and Analysis ............................................................... 29 Introduction ......................................................................................... 29 Define Phase ...................................................................................... 29 Measure Phase ................................................................................... 35 Analyze and Improve Phases ............................................................. 51 Summary ............................................................................................. 66 V. Results, Conclusion, and Recommendations ........................................... 67 Introduction ......................................................................................... 67 Questions and Answers ...................................................................... 67 Results ................................................................................................ 68 Conclusion .......................................................................................... 74 Recommendations .............................................................................. 76 References .......................................................................................................... 77 Appendices A. Instructions for Iron Demand Scheduling File ........................................... 79 B. Control Plan for Process Monitoring ......................................................... 80 5 List of Tables Table Page 1. Six Sigma DMAIC Framework .................................................................. 24 2. SIPOC for Melting Process ....................................................................... 29 3. SIPOC for Molding Process ...................................................................... 30 4. SIPOC for Cleaning Process .................................................................... 32 5. Critical-to-Quality Characteristics ............................................................. 34 6. CTQ to KPOV Relationship Matrix ........................................................... 34 7. Production Delays Log in Melt Department from Jan 2014 to Sept 2014 .................................................................................................... 36 8. Monthly Runner Hand-up Delay from Jan 2013 to Sept 2014 .................. 38 9. Monthly Production of Base Iron and Slag from Jan 2013 to Sept 2014 ............................................................................................ 41 10. North and South Melters Monthly Iron Output .......................................... 44 11. WOI and HF Delays Percentage from Jan 2013 to Sep 2014 .................. 46 12. Information for Potential Saving Calculations ........................................... 50 13. Potential Saving Calculations ................................................................... 51 14. North and South Melters Iron Temperature Increment in Furnace after Furnace Powered Up .......................................................................... 61 15. Combined Iron Demand for Top 10 BMD and DISA Parts ........................ 65 16. Monthly Runner Hang-up Delay from Oct 2014 to March 2015 ................ 68 6 Table ................................ ............................................................................. Page 17. North and South Melters Monthly Iron Output from Oct 2014 to March 2015 ......................................................................................... 70 18. WOI and HF Delays Percentage from Oct 2014 to March 2015 ............... 71 19. Potential Saving Calculations ................................................................... 74 7 List of Figures Figure Page 1. Coreless induction furnace ....................................................................... 16 2. Foundry plant process map ...................................................................... 17 3. Key terms in sand casting ........................................................................ 18 4. Melting process map ................................................................................ 30 5. BMD molding process map ...................................................................... 31 6. DISA molding process map ...................................................................... 31 7. BMD cleaning process map .....................................................................
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