A case study: applying Lean Six Sigma concepts to design a more efficient airfoil extrusion shimming process. (18th April 2011)

• Record Type: Journal Article
• Authors: Hardeman, Claiborne; Goethals, Paul L.
• Is Part Of: International journal of six sigma and competitive advantage. Volume 6:Number 3(2011)
• Page Start: 173
• Page End: 196
• Publication Date: 2011-04-18
• Subjects: define measure analyse improve control -- DMAIC -- lean six sigma -- critical-to-quality scorecard -- failure mode and effects analysis -- shimming process -- airfoil extrusion -- process design -- screw press -- compressor airfoils -- compressor blades -- gas turbines -- product quality -- product defects -- process improvement; Six sigma (Quality control standard) -- Periodicals; Quality control -- Periodicals; 658.4013
• Languages: English
• ISSNs: 1479-2494

Abstract

When the objective of the manufacturer is to eliminate waste or create a more efficient process, innovative techniques are often sought for process improvement. The statistical tools used by Six Sigma practitioners are specifically designed for this purpose; they are frequently used to address problems across a wide number of production systems. Each manufacturing application, however, brings a unique array of potential causes and effects that must be considered to properly model process behaviour. This paper specifically examines a shimming process for a mechanically-driven screw press, whereby compressor airfoils (blades) are produced for a gas turbine. To enhance product quality and identify improvements in process performance, the five-phase approach to problem solving used in Six Sigma projects is applied. As a result of the changes implemented in this case study, the product defect level is reduced by as much as 94% and the Six Sigma rating is increased from 0.868 to 3.207.