Process improvement of fiber glass industry

Abstract

Six Sigma is a structured, statistical and logical method for process improvement. It primarily focuses on increasing the process capability by reducing process variation. This paper aims to reduce process variation of Chopped Strand Mat (CSM) in a fiber industry in the state of Goa, India. The CSM is used in automobile, aerospace, marine and many other industrial applications as housing or cover shells where strength to weight ratio is important parameter in design. The major critical to quality characteristic of CSM is GSM of fiber, where any variation in GSM of fiber leads to variation in CSM. DMAIC methodology is implemented to optimize the fiber production process and reducing process variation. Critical process parameters have been identified using brainstorming and multi-voting method. Taguchi method of experimental design has been used to identify key factors and their optimal levels. Reduction of variance coupled with an economic analysis has been carried out and reported in the paper.