CHAPTER 1

INTRODUCTION

1. 1. INTRODUCTION
Today many of the small scale manufacturing companies in United States are facing problems in
order to become competitive in global market. One of the reasons is the manufacturing activities
are outsourced to low labor cost countries like India and China. (Khan, Z, 2010) Now-a-Days
due to an increased competition companies are looking forward to reduce total cost, lead times
and increasing the product quality. This has created a need to implement lean and six sigma
strategies in manufacturing organizations. Lean Six Sigma approach to business process
improvement helps companies distinguish themselves from competitors by manufacturing
products with less waste, faster, better and at lower cost. Lean Six Sigma is a methodology, when
it implemented properly the company improves efficiency and gain competitive edge. Today
organizations are using different tools and techniques to improve and sustain in the market.
Currently, Six Sigma tools and Lean Management are recognized as most popular continuous
improvement initiatives and companies are using them widely. Lean Six Sigma project initiatives
start with understanding the current state of the Business processes in organization, then setting
up targets for future state of all activities. Six Sigma uses DMAIC (Define, Measure Analyze
Improve and Control) framework and Lean uses tools like value stream mapping,5S program,
Single piece flow etc. Using these tools and techniques organization can improve business
processes, the obstacles to achieve these improvements can be addressed by kaizen event. (Chen,
2010)
This project shows reduce the coolant consumption in tractor rim liners. To reduce the coolant
consumption by applying Lean Six Sigma tools such as Cause and Effect diagrams, root cause
analysis and brainstorming etc. This Project addressed the root causes of problems in the process
of coolant consumption and recommended solutions and alternatives which led to more
optimized processes and enhanced the operational system, eliminate different type of waste, and
increased the profit.

1.2 COMPANY BACKGROUND

1.3 LEAN MANAGEMENT & SIX SIGMA

A lean system emphasizes the prevention of waste in terms of any extra time, labor, or material
spent producing a product or service that doesnt add value to it. A lean systems unique tools,
techniques, and methods can help organization to reduce costs, achieve just-in-time delivery, and
shorten lead times. As Lean systems are customer focused and driven this approach makes sure
that products or services produced and delivered at right time in right quantity at right location at
right time with minimum costs incurred. A lean system allows production of a wide variety of
products or services, efficient and rapid changeover among them as needed, efficient response to
fluctuating demand, and increased quality. Lean approach encourages the rapid response to
customer ever changing demands with focus on mass customizations rather than mass
production. Lean systems make the work flow more efficient, productive, and flexible to changes
in requirements. (Maclnnes, 2002)
Six Sigma is a fact-based, data-driven philosophy of quality improvement that values defect
prevention over defect detection. (Brassard, 2002) Six Sigma is also business philosophy of
focusing on continuous improvement by understanding customer needs, understanding current
business processes, and applying data collection methods. It is also methodology for organization
to make sure those improvements done to improve the key processes. Six sigma tools and
techniques also used to identify which business process in the organization would be benefited
most due to improvement effort.
1.3.1 Brainstorming
It is a group or individual creativity technique by which efforts are made to find a
conclusion for a specific problem by gathering a list of ideas spontaneously contributed by its
members.

1.3.2 Cause and effect diagram

It is also called fish bone diagram show the significant and insignificant actions during a
process. It identifies many possible causes for an effect or problem and sorts the ideas into useful
categories.

Often the experience of the specialized knowledge of engineers and scientists

dominate the selection of factors.

1.3.3 Root Cause Analysis
The Five Whys approach to root cause analysis is often used for investigations into equipment
failure events and workplace safety incidents. The apparent simplicity of the 5-Whys leads
people to use it, but its simplicity hides the intricacy in the methodology and people can
unwittingly apply it wrongly. They end up fixing problems that did not cause the failure incident
and miss the problems that led to it. They work on the wrong things, thinking that because they
used the 5-Whys and the questions were answered, they must have found the real root cause.
1.4 OBJECTIVE OF THE STUDY
To determine the most critical Xs in the coolant consumption process and to eliminate the Vital
Xs in the process to reduce the coolant consumption in tractor rim line.
1.5 ORGANIZATION OF THE REPORT
This section provides a brief overview of the chapters for the convenience of the reader to easily
explore the contents of the report. In chapter2 deals with literature review on reduce the coolant
consumption process using lean six sigma methodology. The problem statement and
methodology in chapter 3.Chapter4 DMAIC methodology is discussed. The chapter5 discussed
in Conclusion and future study.

CHAPTER 2
LITERATURE REVIEW
3

Various work done on the welding process, optimization of weld parameters by using the
statistical optimization techniques are presented in the chapter.
2.1 TIG welding & Taguchi technique
Nirmalendhu,et al., (2014) analyzed to the improvement of ultimate load of stainless
steel mild steel weld specimen made of tungsten inert gas (TIG) welding. L16 orthogonal array
(OA) of Taguchi method has been used to conduct the experiments using several levels of
current, gas flow rate and filler rod diameter. Statistical techniques analysis of variance
(ANOVA), signal-to-noise (S/N) ratio and graphical main effect plots have been used to study
the effects of welding parameters on ultimate load of weld specimen. The optimum welding
condition obtained by Taguchi method is: current = 100 A, gas flow rate = 18 l/min and filler rod
= 2 mm. Confirmation test is confirms the improvement of the UL which also indicates the
validity of the present optimization.
Avinash,et al.,(2013)are analyzed to friction welding, the joints are formed in the solid
state by utilizing the heat generated by friction. This study are obtaining friction weld element of
Aluminum 6351, steel 304 and optimizing the friction welding parameters in order to establish
the weld quality. This paper discusses use Taguchi experiment design technique for maximizing
tensile strength of friction welding Al (6061) and steel 304.An orthogonal array of L9 was; Using
ANOVA and signal to noise ratio of robust design, effect of tensile strength of friction welding
process parameter (Rotational speed, forging force, time) is evaluated and optimum welding
condition for maximizing tensile strength is determined. It is found that the parameter design of
Taguchi method provides a simple, systematic, and efficient methodology for the optimization of
the Friction welding parameters. While the application of optimization techniques on Friction
welding reveals an increasing trend in the literature, it is important to recognize practical
limitations of the process parameters.
Anoop, et al., (2013) studied the Aluminium alloy 7039 is an Al-Mg-Zn alloy employed
in aircraft, automobiles, infantry combat vehicles and high speed trains due to their low density,
high specific strength and excellent corrosion resistance. Pulsed Gas Tungsten Arc Welding is
used in this study for welding AA7039. The influence of the various GTAW process parameters,
i.e. Pulse Current, Base current and Pulse Frequency on were studied welds for properties of
weld like microhardness, ASTM grain size number and heat affected zone (HAZ) width.
4

Orthogonal arrays of Taguchi, the signal-to-noise (S/N) ratio, the analysis of variance
(ANOVA), and regression analyses are employed to find the optimal process parameter levels
and to analyze the effect of these parameters on the weld properties. Confirmation test with the
optimal levels of welding parameters was carried out in order to illustrate the effectiveness of the
Taguchi optimization method. From the analysis of the results using the signal-to-noise (S/N)
ratio approach, analysis of variance and Taguchis optimization method, the following can be
concluded: Peak current of 150A, base current of 75A and pulse frequency of 150 Hz are the
optimized welding parameters for getting highest microhardness, smallest eqiuxed weld grains
and minimum HAZ width. Out of three selected parameters, peak current has the highest
contribution i.e. 61.58%.
Pasupathy,et al., (2013) presented the influence of welding parameters like welding
current, welding speed on strength of low carbon steel on AA1050 material during welding. A
plan of experiments based on Taguchi technique has been used to acquire the data. An
Orthogonal array, signal to noise (S/N) ratio and analysis of variance (ANOVA) are employed to
investigate the welding characteristics of dissimilar joint and optimize the welding parameters.
Finally the conformations tests have been carried out to compare the predicted values with the
experimental values to confirm its effectiveness in the analysis of strength.The experi-ment value
that is observed from optimal welding parameters, the strength is 61.37MPa. & S/N ratio is
16.45.
Sathish,et al., (2012) reported the work in welding of dissimilar metals, carbon steel and
stainless steel pipes which find wide application in the field of chemical, oil and petroleum
industries. GTAW (Gas Tungsten Arc Welding) process is used. Carbon steel pipe specimen
(A106 Grade B) and stainless steel pipe specimen (A312 TP 316L) of 6 ID, thickness 7.11mm
and length 150 mm each were selected.
Taguchi method is used to formulate the experimental layout to rank the welding input
parameters which affects the quality of the weld and is influenced by the parameters like gas
flow rate followed by current and bevel angle. The percentage contribution of each parameter
and prediction of tensile strength is found by analysis of variance (ANOVA) technique. The
optimum range includes current of 110 to 115 amperes, shielding gas flow rate of 12.5 LPM, and
bevel angle of 45 degrees.

Kishore,etal., (2010) have analyzed the effect of process parameters in qualitative manner
for welding of AISI1040 steel using processes of Shielded Metal Gas Welding (MIG and TIG).
Taguchi method is used to formulate the experimental layout arc voltage, arc current, welding
speed, nozzle to work distance and gas pressure predominantly influence weld quality, even plate
thickness and backing plate too have their own effect. Design of experiments based on
orthogonal array is employed to develop the weldments. An L8 orthogonal array is selected for
experimentation. The total variables are seven hence 2 7 experiments are required for perfect
analysis, however it is impractical, time consuming and expensive to conduct such large number
of experiments .
The result computed is in form of contribution from each parameter, through which
optimal parameters are identified for minimum defects. The experiments with low current has
increased the % of variance of LOP in both TIG and MIG welding .High welding speed resulted
in under fill; it is as high as 8mm2 in TIG welding; Lack of penetration is largely influenced by
the plate thickness in TIG welding; current has an influence of about 45 % on under fill;
2.2 Spatter Defects
Teeradej, et al., (2010) studied to determine an optimal condition of resistant spot welding
process in order to reduce a welding spatter problem. there were four factors considered as high
potential causes of welding spatters. They selected the factors are Electrical supply single
,dual,Material

thickness-

heavy

,normal,

Welding

angle-

perpendicular,

non

perpendicular,Welding position- middle,flange Each factor consider as three levels and 2

factorial experiment also conducted to test the effects of all possible combinations.
The result showed that three main factors namely E, WA, and WP had significant effects to
the defective parts whereas T was not significant.The optimal condition obtained from the
experiments by using single pulse signal, normal thickness, perpendicular angle, and middle
position, a number of defective parts were reduced significantly from 12% to 3.67%.

CHAPTER 3
PROBLEM STATEMENT AND METHODOLOGY
3.1 Proposed Methodologies
3.1.1 DMAIC Methodology
DMAIC methodology involves 5 steps Define, Measure, Analyze, Improve, and Control. This
method can be used to improve the current capabilities of current process where based on data
driven conclusions future state can be established.
Define Phase: The goal of define phase is to define the project scope by understanding
background information about the process and its customers. Tools used in define phase as voice
of customer, project charter are used decide the scope of project and define boundaries of
improvement effort. It also identifies key stakeholders, time lines, improvement priorities, and
improvement targets at the beginning of project. The best representation of define phase can be
established by Hoshin planning or x matrix.
Measure Phase: The goal of measure phase is to focus on improvement effort by gathering
information about current state of the process. Team has created data collection templates
according the area of improvement and worked on getting first hand data. Measuring the right
data which can pin point location, occurrence point and rate of occurrence is required to decide
the improvement priority and problems location. In measure phase team can gather Historical
data to come up with baseline for improvement. Measure phase data collection effort leads to
more focused problem statement.
Analyze Phase: The goal of analyze phase is to establish the root causes of the problem and
confirm them with the data points. Analyze phase helps in collecting causes of the problem to
come up with root causes. Braining storming, cause and effect diagram, histogram and fishbone
diagram are some of the tools which can be used in analyze phase of the improvement.
Improve Phase: The goal of improve phase to work on improvement solutions based on define,
measure and analyze phase outputs. Improve phase compares before and after process status to
develop and implement the process improvements. Improve phase not only generates the
solutions but also give feedback mechanism check the effectiveness of improvements.
7

Control Phase: The goal of the control phase is to maintain and standardize the gains of the
improvements. Control phase also require a continuous improvement effort to sustain the change.
Customer changing requirements need major changes in process flows; in that case improvement
team should be able to analyze the changes for further improvements.

CHAPTER 4
DMAIC METHODOLOGY
4.1 DEFINE

The Problem is defined in this phase. Reduction of coolant consumption in tractor RIM line is
targeted. With the help of process mapping, various stages in the rims process are identified is
shows the figure 4.1.
Problem Statement: Reduction of coolant consumption in tractor RIM line
Project Scope: Rework cost reduction & Quality improve
Target: Monthly 500 litres to 200 litres

Fig 4.1: Process Map of Tractor Rim Line

4.1.1 Identification of the Problem

The problem description helps where the problem is located/occurred is shown in the table 4.1.
Table 4.1: Identification of Problem

4.1.1.2 Categorization

A=13

B=4

C=2

TYPE A Minimum involvement of other department in solving them / can be solved by

the QC member itself.

TYPE B Involvement of other department is a necessity.

TYPE C Problem can be solved with management assistance.

4.1.2 Selection of Problem

10

To identify the problem is located in RIM line. Then to found the causes of the problem is based
on ranking related to product, quality, cost, delivery, service, work environment is shows table
no.4.2.
Table 4.2: Selection of problem

P-Production, Q-Quality, C-Cost, D-Delivery, S-Safety, WE-Work Environment

4.2 Measure Phase
During this phase, the key processes in the project lifecycle that affect the CTQ (in this case,
product quality), were identified to be project study, execution and delivery. Measurements
related to the CTQ are made in these phases. The field errors captured by the 4W&1H,root cause
& WHY -WHY analysis as shown in Figure 4.2.1.
4.2.1 4W & 1H Analysis
The 4W &1H is explained the WHAT is the problem and WHERE it is occur and WHEN it is
occur, WHO & HOW much is the severity of the problem/process as shown in the figure 4.2.1.

11

F
ig 4.2.1: 4W&1H

4.2.2 Root Causes & Why -Why Analysis

It is one of the simplest investigation tools easily completed without statistical analysis. Also
known as a Why Tree, it is supposedly a simple form of root cause analysis. By repeatedly
asking the question, Why? you peel away layers of issues and symptoms that can lead to the
root cause of the coolant consumption as shown in figure 4.2.2.

Rim scuffing and scoring mark high

Why?

Rim operation improper lubrication used

Why?

Coolant contamination changed

Why?

Foreign particles mix-up

Why?

During the operation iron parts mixed and set up

time excess grease used
Why?

Exist design11
A System to be provided to Re coolant cycle system
COUNTER MEASURE
12

Fig 4.2.2: WHY-WHY analysis

4.3 Analyze phase: Process performance was assessed using Cause-and Effect diagrams, to
isolate key problem areas, to study the causes for the deviation from ideal performance, and to
identify if there is a relationship between the variables. Extensive brain-storming sessions were
held with team members to evolve these diagrams. Figure 4.3.1 shows the Cause-and-Effect
diagrams for project. The probable causes that can lead to quality nonconformance in a project
during different phases of a project life cycle were listed Data analysis is carried out in this phase
to find the reasons for consumption of rims coolant.
4.3.1 Identification of Causes
To identify the root cause of the problem using the lean six sigma methodology like
brainstorming, WHY-WHY analysis and cause and effect diagram etc.,
4.3.1.1 Brain Storming
Improper coolant oil and water mix up
Improper Coolant flow
Coolant contamination
Coolant spillage in floor
Tool life gone
Tool jaw not sufficient.
Improper tool loading setting
Excess material Thickness
Improper tool setting
Hydraulic leakage oil mix up
Waste and grease mixed coolant
Improper coolant pipe line routing
13

4.3.1.2 Cause and Effect diagram

Large variation has been reported in the first phase. To reduce variations, analyze the machine
and identify some factors which may affect the variation. Finally, a fishbone diagram is formed
as shown in Figure 4.3.1.

Fig 4.3.1 Cause & Effect Diagram

4.3.1.3 Validation of Causes

To validate the each effects from the cause and effect diagram which is leads to causes of the
problem. To segregate the each causes based on major & minor effects and to eliminate the
minor effects and solve the major causes of the problem as shown in table 4.3.1.

Table 4.3.1 Method for Considering the Causes

14

CONSIDERED / NOT

REASON FOR

CONSIDERED

ELIMINATION

M S

PROBLEM

Man

Improper coolant oil mixed

Considered

Man

Unskilled operator

Considered

Man

Improper coolant oil flow

Considered

SOP Available

Man

Incorrect Location of rim

Not considered

Periodic PM

Man

Tool life gone

Not considered

Periodic Inspection

Coolant contamination

Considered

Machin
e

Method Tool jaw not sufficient

Not considered

Man

Coolant spillage in floor

Considered

Lesser thickness material

Not considered

Materia
l
Method

Method

Waste and grease mixed

coolant oil
Improper coolant pipe
routing

Machin Leakage hyd oil mixed for

e

coolant

Periodic PM

Check point in First off

inspection

Considered

Not considered

Considered

4.3.1.4 After Elimination of Minor Effects - Causes & Effect Diagram

15

Expanding Block setting by

PTA

Fig 4.3.2 Elimination of Minor Effects

4.3.1.5 Effects of the Problem
Rim Rework more
Rim quality effect for rim rust form problem high
Rim scuffing mark and scoring mark high
Our internal customer Rim feeding time delay
Pickling cost very high
High operator fatigue and Skilled operator is required
4.3.1.6 Importance of the Problem:
Machine bit accumulated coolant oil daily cleaning and fill up the barrel .
Weekly 6 barrel Moved to ETP plant
Coolant removed out extra 2man power and barrel moved forklift required
Effect coolant spillage floor
Coning machine separate coolant used
Monthly coolant oil consumption 500 Lts
16

4.4 Improve phase

In the improve phase, first make some improvements based on results of the analyze phase and
assess the reduction of rim line coolant consumption system. Based on current process flow, to
eliminate the root causes of the problem and improved process flows. So it has decided to
improve these problems by understanding current process flows and developing improved
process flows to address the causes of more consumption rate. The coolant recycle unit machine
as shown in figure 4.4.1, magnetic fitter is shown in 4.4.2, oil skimmer shown in 4.4.3 & before
and after machine set up shown in 4.4.4.
4.4.1 Developing Solution
A coolant recycling unit introduced
Iron parts removed out purpose magnetic duct collator
Bucket 20 micron paper filter unit
Coolant mixed oil removed purpose oil skimmer unit provided
This unit connects the three machines

Coning
Roll former 1
Roll former 2

F
ig 4.4.1: Coolant Recycle Unit
17

Fig 4.4.2: Magnetic Filter Unit

Fig 4.4.3: Oil Skimmer Unit

18

Fig 4.4.3: Before & After Coolant Tank

4.5 Control phase: Various measures identified to improve the process are documented and
institutionalized. Control phase established to monitor the process of coolant recycle unit.
4.5.1 Benefits
Tangible Benefits
Rust free
Cost saving directly
Rework reduced
Productivity improved
Breakdown occurrence reduced

19

Intangible Benefits
Operator fatigue reduced
SOC Eliminated
Improved Safety
Gain Confident to solve problems
Job Satisfaction

20

CHAPTER 5
CONCLUSION

5.1 Future Study

21

REFERENCES

1. Avinash s. PachaL, Amol bagesar Taguchi Optimization of Process Parameters in Friction

welding of 6061 Aluminium Alloy and 304 Steel International Journal of Emerging Technology
and Advanced Engineering Volume 3, April 2013.
2.Anoop C A, Pawan KumarApplication of Taguchi Methods and ANOVA in GTAW Process
Parameters Optimization for Aluminium Alloy 7039 International Journal of Engineering and
Innovative Technology (IJEIT) Volume 2, May 2013
3.J.Pasupathy, V.Ravisankar Parametric optimization of tig welding parameters using taguchi
method for dissimilar joint International Journal of Scientific & Engineering Research, Vol. 4,
Nov.2013.
4.R.Sathish, B.Naveen, P.Nijanthan,K.Arun Vasantha Geethan, Vaddi Seshagiri Rao Weldability
and process parameter optimization of dissimilar pipe joints using GTAW International Journal
of Engineering Research and Applications (IJERA) Vol. 2, Issue 3, May-Jun 2012, pp.2525-2530
5. Kishore K, P. V. Gopal Krishna, K. Veladri and Syed Qasim Ali ,Analysis of defects in gas
shielded arc welding of aisi1040 steel using taguchi method , ARPN Journal of Engineering
and Applied Sciences- Jan 2010.
6.Teeradej Wuttipornpun Analysis of Welding Factors to Determine an Optimal Condition of
Resistant Spot Welding Process The Journal of KMUTNB., Vol. 20, Jan. - Apr. 2010
7.Krishnaiah K, Shahabudeen P, Applied design of experiments and taguchi methods ,PHI
learning pvt ltd-Delh 2013.
8.Kkrishnaiah K, Applied statistical quality control and improvement ,PHI learning pvt Ltd
Delhi-2013.
9. Ahmed Khalid Hussain, Abdul Lateef, Mohd Javed, Pramesh.T, Influence of welding speed
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Engg Research, Vol.1 No.3, 2010.

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