Cycle Time Reduction in CNC Turning Process Using Six Sigma Methodology – A Manufacturing Case Study
28 Jun 2021-pp 135-146
TL;DR: An experimental study is presented optimizing the cutting parameters while machining of shoulder bolt in a Computer Numerical Control (CNC) turning machine to reduce the cycle time, which resulted in increased productivity and also in annual savings.
Abstract: Six-Sigma, a data-driven methodology, employed to improve the process in terms of Defect reduction or process optimization. In this paper, an experimental study is presented optimizing the cutting parameters while machining of shoulder bolt in a Computer Numerical Control (CNC) turning machine to reduce the cycle time. This study identifies, the effects of cutting speed, feed rate and dwell time on Thread rolling diameter (TRD) in CNC turning machine that was experimentally investigated. The experimentation plan is designed using six sigma D-M-A-I-C methodology, and the subsequent statistical analysis has been done using Minitab-16 software. Shainin based variable search tool has been used to investigate the design parameters that contribute to the reduction of the cycle time and factorial plots are employed to determine the contribution of important parameters. Later, the optimal values for the best cutting conditions are proposed for industrial production using the formulated mathematical model. Finally, this paper documents the analysis and tasks performed that reduced cycle time which resulted in increased productivity and also in annual savings.
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TL;DR: In this paper , the authors analyse the perception of six sigma process capabilities in automotive supply chains assuming differences in company size, supply chain rank and 6 sigma duration, and find that mainly small companies inhibit a risk for the supply chain.
Abstract: Six sigma is understood as a technique for the continuous improvement in process quality; however, it has been rarely scientifically analysed in small- and medium-sized enterprises (SMEs). SMEs representthe vast majority of enterprises throughout economies and contribute to automotive supply chains in various tier ranks. As SMEs are known to lack resources and skills while focusing on short-term benefits rather than on long-term gradual improvements, the aim of of this paper is to analyse the perception of six sigma process capabilities in automotive supply chains assuming differences in company size, supply chain rank and six sigma duration. This was tested with Fisher’s exact test. Companies with less than 1000 employees, subsuppliers and companies with a six sigma implementation in the last 3 years struggled to meet six sigma principles, suggesting that mainly small companies inhibit a risk for the supply chain. These findings contribute to the existing theoretical body of knowledge by identifying a three-to-five-year period for six sigma implementations until six sigma maturity. Practically, the findings contribute to the research by explaining the need for a continuous supplier development over a three-to-five-year period until the company meets its performance requirements, with a supply chain risk incorporated in lower-tier ranks and with small companies.
1 citations
01 Jan 2022
References
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07 Dec 1999
TL;DR: In this article, it was shown that scale-independent hysteresis can produce switching that is slow-on-the-average and therefore the results mentioned above can be used to study the stability of adaptive control systems.
Abstract: It is shown that switching among stable linear systems results in a stable system provided that switching is "slow-on-the-average". In particular, it is proved that exponential stability is achieved when the number of switches in any finite interval grows linearly with the length of the interval, and the growth rate is sufficiently small. Moreover, the exponential stability is uniform over all switchings with the above property. For switched systems with inputs this guarantees that several input-to-state induced norms are bounded uniformly over all slow-on-the-average switchings. These results extend to classes of nonlinear switched systems that satisfy suitable uniformity assumptions. In this paper it is also shown that, in a supervisory control context, scale-independent hysteresis can produce switching that is slow-on-the-average and therefore the results mentioned above can be used to study the stability of hysteresis-based adaptive control systems.
2,197 citations
01 Jan 1999
TL;DR: In this article, it was shown that switching among stable linear systems results in a stable system provided that switching is slow-on-the-average, i.e., the number of switches in any nite interval grows linearly with the length of the interval, and the growth rate is suciently small.
Abstract: It is shown that switching among stable linear systems results in a stable system provided that switching is \slow-on-the-average." In particular, it is proved that exponential stability is achieved when the number of switches in any nite interval grows linearly with the length of the interval, and the growth rate is suciently small. Moreover, the exponential stability is uniform over all switchings with the above property. For switched systems with inputs this guarantees that several input-to-state induced norms are bounded uniformly over all slow-on-the-average switchings. These results extend to classes of nonlinear switched systems that satisfy suitable uniformity assumptions. In this paper it is also shown that, in a supervisory control context, scale-independent hysteresis can produce switching that is slow-on-the-average and therefore the results mentioned above can be used to study the stability of hysteresis-based adaptive control systems.
2,028 citations
TL;DR: In this paper, the Taguchi method was used to find the optimal cutting parameters for turning operations, and the main cutting parameters that affect the cutting performance in turning operations were found.
1,186 citations
Book•
01 Jan 2000
TL;DR: This book presents an Executive Overview of Six Sigma, a Powerful Strategy for Sustained Success, and some of the key concepts of the Six Sigma System as well as tools used in expanding & Integrating the six Sigma System.
Abstract: Part I: An Executive Overview of Six Sigma. Chapter 1: A Powerful Strategy for Sustained Success. Chapter 2: Key Concepts of the Six Sigma System. Chapter 3: Why Is Six Sigma Succeeding Where Total Quality "Failed"? Chapter 4: Applying Six Sigma to Service and Manufacturing. Chapter 5: The Six Sigma Roadmap. Part II: Gearing Up and Adapting Six Sigma to Your Organization. Chapter 6: Is Six Sigma Right for Us Now? Chapter 7: How and Where Should We Start Our Efforts? Chapter 8: The Politics of Six Sigma: Preparing Leaders to Launch and Guide the Effort. Chapter 9: Preparing Black Belts and Other Key Roles. Chapter 10: Training the Organization for Six Sigma. Part III: Implementing Six Sigma: The Roadmap and Tools. Chapter 12: Identifying Core Processes and Key Customers (Roadmap Step 1). Chapter 13: Defining Customer Requirements (Roadmap Step 2). Chapter 14: Measuring Current Performance (Roadmap Step 3). Chapter 15: Six Sigma Process Improvement (Roadmap Step 4). Chapter 16: Six Sigma Process Improvement (Roadmap Step 4A). Chapter 17: Expanding & Integrating the Six Sigma System (Roadmap Step 5). Chapter 18: Advanced Six Sigma Tools: An Overview. Conclusion: Twelve Keys to Success.
1,017 citations
TL;DR: In this paper, the Taguchi method was used to find the optimal cutting parameters for surface roughness in turning of AISI 1030 steel bars using TiN coated tools.
642 citations