Defect reduction in steel manufacturing company using DMAIC approach

Defect reduction in steel manufacturing company using DMAIC approach

Mr. Sadesh K

Department of Mechanical Engineering

PSG College of Technology

Coimbatore, India

ksh.mech@psgtech.ac.in

G Nitish Reddy

Department of Mechanical Engineering

PSG College of Technology

Coimbatore, India

nitishreddy21042001@gmail.com

Abstract:

In pursuit of operational excellence, a leading steel manufacturing company specializing in ingots, implemented the DMAIC (Define, Measure, Analyze, Improve, Control) methodology to systematically reduce defects and minimize waste. The company achieved a significant improvement, reducing the defect rate from 2.38% to 0.86837%, marking a 63.52% reduction. This enhancement elevated the process sigma level to 4.25. With a strong focus on continuous improvement, the organization now aims to achieve a 5 sigma level, reflecting world-class quality standards and further optimizing production efficiency while maintaining customer satisfaction and sustainability across operations.

Keywords: DMAIC Methodology, Waste Minimization, Ingot Production, Lean Six Sigma, Defect Rate, Sigma Level, Continuous Improvement.