WRAP THE SCRAP WITH DMAIC. Strategic Deployment of Six Sigma in Indian Foundry SMEs

Six Sigma approach is generally employed to improve the sigma level of manufacturing or service processes by reducing their deviations and defects. Six Sigma provides the opportunity to eliminate mistakes, improve morale and save money. Doing things right in first time and keeping them consistent is the only idea behind Six Sigma. Its fundamental objective is to achieve customer satisfaction with continuous improvement in quality and productivity. Mostly we are emphasizing on various tools or techniques being used during DMAIC projects and almost ignore the procedure to execute different phases of the Six Sigma project. This book provides unique step by step methodologies to perform Define, Measure, Analyse, Improve and Control phases of a Six Sigma project, respectively. An empirical investigation has been carried out in a make-to-order type (medium sized) foundry and Six Sigma is successfully implemented by decreasing the scrap of piston castings, appreciably. The book focuses on scrap reduction specifically in Indian foundries and tries to find out the reasons of low productivity index. It also tends to shatter the various phobias of SMEs in context of Six Sigma by validating the compatibility of proposed methodologies through a successful case study in Indian foundry environments.

Dr. BIKRAM JIT SINGH is working as a Professor in Mechanical Engineering Department of Maharishi Markandeshwar University, Sadopur, Ambala (Haryana). He is PhD. from National Institute of Technology, Kurukshetra on Six Sigma and has done Masters of Engineering with distinction in Industrial Engineering from Thapar University, Patiala. He has a three year Professional Experience as a Manager in Light Alloy Foundry at FEDRAL MOGUL, INDIA (A US based Multi-National at Bahadurgarh, India.). He was undergone on the job training on SAP (PP-Module), QS-9000, ISO-TS 16949, SQC Tools and TPM for 2 years. He had worked as Lecturer in Mechanical Engineering Department for Two Years at RIMT-Institute of Engineering & Technology, Mandi Gobindgarh, India. He was also posted as HOD-Mechanical at BBSBPC, Fatehgarh Sahib, India for One Year. He has around 15 International Journal publications along with paper presented in number of International and National Conferences. He is a main and corresponding Author and can be contacted at chann461@yahoo.com .