Advances in Production Engineering & Management
Volume 11 | Number 1 | March 2016 | pp 59–69
http://dx.doi.org/10.14743/apem2016.1.210
Aluminium hot extrusion process capability improvement using Six Sigma
Ketan, H.; Nassir, M.
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A B S T R A C T
In this work, the Six Sigma (Define-Measure-Analyse-Improve-Control) DMAIC methodology has been followed to explain the original problem of lowering extrusion process variation and improving the process capability based on the determined Critical Quality Characteristics (CQC). The extrusion process charter worksheet is recognized, a SIPOC (Supplier-Input-Process-Output-Customer) chart is constructed and a Pareto chart is drawn in the Define phase of the methodology. Measurement data are collected, verifying process stability and verifying process normality by using X̄-R charts and normality test, respectively. Process capacity index, sigma levels, defects per million opportunities (DPMO) determination in the measure phase using a Histogram. During Analyse phase, Cause and Effect diagram are established to determine their likelihood for the root cause of aluminium extrusion defective products. The suggested solutions are installed in the improve phase. In the Control phase, all tools are applied in the Measure phase are repeated to determine the improvement level. The DMAIC methodology has been applied in the (Ur state company for engineering industries)/(aluminium extrusion factory). The Minitab 16 Software is used for calculations and plot charts. The results for the internal dimension (X1) of the corner section product indicate a reduction in DPMO from 536804 to 185795.09, sigma level is improved from 1.4 to 2.4, process yield (Y) is improved from 46 % to 81 %, and profit is improved from ID 127.000 to ID 223.000 per 1000 kg.
A R T I C L E I N F O
Keywords • Aluminium extrusion process, Six Sigma, DMAIC, Critical quality characteristics, Profit
Corresponding author • Ketan, H.
Article history • Received 21 April 2014, Revised 3 September 2015, Accepted 20 October 2015
Published on-line • 7 February 2016
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