Roller Chains Quality Enhancement using Six Sigma and Failure Mode and Effects Analysis (FMEA)

Abstract

Roller chain is an important part in the modern manufacturing industry. The purpose of this study was to enhance the quality of roller chains manufacturing process by utilizing Six-Sigma methodology and Failure Mode and Effects Analysis (FMEA). Through these approaches, it was found that pin diameter, pitch length of plate PH, and pitch length of the plate RH had significant effects to the quality of chain stretch. The continuous enhancement process could also reduce waste in the process from 158,629.86 PPM to 3.64 PPM (99.97% reduced). Moreover, the process capability (Cpk) increased from 1.10 to 3.39, (67.55% increased). The proposed Six-Sigma and FMEA approaches could also be applied to other chain stretch manufacturing industries worldwide.