A Comprehensive Study on Implementing Six Sigma Methodology in the Injection Moulding Process for Quality Enhancement

Abstract

Introduction: This study aims to address the challenges faced in the injection moulding process, particularly focusing on reducing defects and improving quality. The study utilizes the Six Sigma DMAIC methodology to identify root causes of defects and suggest improvements in the manufacturing process. Quality improvement is imperative in today's competitive market to meet customer expectations and minimize costs associated with poor quality.

Objectives: The main objective is to identify the problems hindering quality in the injection moulding process and propose effective solutions. Specific objectives include ranking defective parts, identifying factors affecting quality, finding root causes of defects, and suggesting improvements.

Methods: The research employs the DMAIC (Define, Measure, Analyze, Improve, Control) approach, involving data collection, analysis, brainstorming sessions, and implementation of corrective measures. Various quality tools such as Pareto charts, Ishikawa diagrams, and root cause validation sheets are utilized to identify and address issues.

Results: Through data collection and analysis, the study identifies critical defects such as short fill, black dots, and scratches in the injection moulding process. Defect-wise Pareto analysis reveals the most significant contributors to defects, aiding in setting improvement targets. The root cause analysis highlights factors like insufficient injection pressure, inadequate cooling, and operator errors. Proposed improvements include adjusting machine parameters, enhancing training programs, and implementing preventive maintenance measures.

Conclusions: Quality improvement in injection moulding is essential for meeting customer expectations and maintaining competitiveness. The Six Sigma DMAIC methodology provides a structured approach to identify, analyze, and address quality issues effectively. By prioritizing defects, understanding root causes, and implementing targeted improvements, organizations can achieve significant enhancements in product quality and operational efficiency.