The IUP Journal of Operations Management
Assessment of Implementation of Six Sigma DMAIC Approach in a Casting Unit: A Case Study

Article Details
Pub. Date :Nov, 2018
Product Name : The IUP Journal of Operations Management
Product Type : Article
Product Code : IJIT31809
Author Name : Jagdeep Singh, Harwinder Singh and Surjit Kumar Gandhi
Availability : YES
Subject/Domain : Management
Download Format : PDF Format
No. of Pages : 19



Six Sigma approach is a management approach of achieving major enhancements in a process through systematic elimination of waste. In this case, the casting unit under study was experiencing a rejection rate of 30%. The main aim of the study was to identify various causes of occurrence of blowholes and identify corresponding remedies for these defects by systematic implementation of DMAIC cycle. Preventive and corrective actions were recommended to reduce the blowholes defect and overall improvement was validated through two-proportion test. The results of investigation demonstrated the net significant reduction of blowhole defect from 28,111 to 9,708 Parts Per Million (PPM) which resulted in net savings of 1,256,640 annually.


If an existing process is not meeting customer specifications, use of Six Sigma five-phase methodology, Define, Measure, Analyze, Improve, and Control (DMAIC) process can be implemented for better effectiveness and efficiency to achieve better productivity levels. These five phases are:


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