Ravi et. al; International Journal of Advance Research, Ideas and Innovations in Technology © 2018, www.IJARIIT.com All Rights Reserved Page | 1768 ISSN: 2454-132X Impact factor: 4.295 (Volume 4, Issue 3) Available online at: www.ijariit.com Improvement in production rate by reducing the defects of die casting process by DMAIC approach Ravi ravi1704singh@gmail.com Bansal Institute of Science and Technology, Bhopal, Madhya Pradesh Shyam Kumar Barode shyam.kr.0210@gmail.com Bansal Institute of Science and Technology, Bhopal, Madhya Pradesh Sachin Jain sandeshsachin@gmail.com Bansal Institute of Science and Technology, Bhopal, Madhya Pradesh ABSTRACT Six Sigma’s problem-solving methodology DMAIC has been one of several techniques used to improve quality. The work follows the DMAIC methodology to investigate defects, root causes and provide a solution to reduce/eliminate these defects. The analysis from employing Six Sigma and DMAIC indicated that the metal melting temperature, die temperature and die holding time influenced the number of defective items produced. In particular, the design of experiments (DOE) and two-way analysis of variance (ANOVA) techniques were combined to statistically determine the correlation of the metal melting temperature, die temperature and die holding time with defects as well as to define their optimum values needed to reduce/eliminate the defects. As a result, a reduction of 16.93 % to 10.04 % in the terminal cover and 16.62 % to 8.97 % in the din based cover was achieved, which helped the organisation studied to reduce its defects per million opportunities (DPMO) and thus improve its Sigma level from 2.53 to 2.79 for the terminal cover and 2.55 to 2.85 for the din based cover. Keywords: Defects, Productivity, Quality, DMAIC approach, Cause and effect analysis 1. INTRODUCTION The DMAIC is both a philosophy and a methodology that improves quality by analyzing data to find the root cause of quality problems and to implement controls. Although DMAIC implemented to improve manufacturing and business, processes such as product design and supply chain management. It is a business improvement strategy used to improve profitability to drive out waste in the business process and to improve the efficiency of all operation that meets customer’s needs and expectation. DMAIC is a customer-focused program where cross-functional teams work on a project aimed at improving customer satisfaction. It is a scientific method to improve any aspect of a business, organization process. DMAIC is a methodology to 1. Identify improvement opportunities. 2. Define and solve problems 3. Establish measures to sustain the improvement. Six- Sigma is a statistical measurement of only 3.4 defects per million. Six-Sigma is a management philosophy focused on eliminating mistakes, waste and rework. It establishes a measurable status to achieve and embodies a strategic problem-solving method to increase customer. Satisfaction and dramatically reduce cost and increase profits. Six-Sigma gives discipline, structure, and a foundation for solid decision making based on simple statistics. The real power of Six Sigma is simple because it combines people power with process power. The Six Sigma is a financial improvement strategy for an organization and now a day it is being used in many industries. Basically it is a quality improving process of final product by reducing the defects; minimize the variation and improve capability in the manufacturing process. The objective of Six Sigma is to increase the profit margin, improve financial condition through minimizing the defects rate of product. It increases the customer satisfaction, retention and produces the best class product from the best process performance. 2. LITERATURE REVIEW Mohit Chhikara (2017) presented the literature-assessment of the works already carried out inside the discipline of Six Sigma Implementation by using the various authors till now. The findings of this paper might be the premise of my similarly research in this field with the aid of developing suitable research technique needed to achieve the targets set via me for my research work. Rajat Ajmera and Valase K.G. (2017) explore using DMAIC methodology of six sigma to decrease the defect in a specific textile industry. That is a scientific technique in the direction of defects minimization thru 5 stages of DMAIC technique named define,