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Abstract
A defect in castings does not just happen. Casting defects are unusually not by accidents, they occurbecause some step in manufacturing cycle does not get properly controlled and somewhere something goes wrong. They are caused by wrong practice in one or more of the basic operations involved in the casting process as in the equipment used, or by the design of the part. A defect may be the result of a single clearly defined cause or a combination of factors, in which case necessary preventive measures are more obscure. If not controlled the amount of rejection it may be increased randomly. In this paper our work is to identify the major occurrence defects from a leading foundry industry in Tamilnadu, which we have visited for 36 days and monitor the production of castings and identify some defects for different 12 products, the total production quantity of that 12 products are 17,365 and total amount of rejection is 1407, with the help of SixSigma (DMAIC) method we have identified that Cold Metal defect which is the major defect from that 12 productswhich affects the quality, more when compared to other defects, so we have taken the cold metal defect and identified the root causes and suggested some remedies to control the occurrences of the cold metal defect, so that the defective products where reduced when compared to the previous rejection percentage.