Data mining driven DMAIC framework for improving foundry quality – a case study

Six Sigma Define-Measure-Analyze-Improve-Control (DMAIC) methodology has been widely used across industries as the best systematic and data driven problem solving approach for quality improvement. Statistical Design of Experiment (DOE) is used in the ‘Improve’ stage for obtaining optimal process settings for significant variables contributing towards quality improvement. But, DOE is an offline activity requiring time and other resources for conducting experiments and analyses. Further, there are many small and medium scale enterprises that cannot afford to conduct DOE. Under such practical constraints, it is desirable to apply DMAIC using online process data under day-to-day production situations or with little changes in process settings without compromising production. In this article, we propose a DMAIC framework, driven by data mining techniques for defect diagnosis and quality improvement where historical and online process data can be effectively utilised. We have used two decision tree algorithms namely, Classification and Regression Tree and Chi-squared Automatic Interaction Detection in developing the proposed framework. The proposed approach is applied in an Indian grey iron foundry where conducting DOE is not a feasible option for the management. The result demonstrates a significant reduction in casting defect and validates the practical viability of this approach.