International Journal of Science, Engineering and TechnologyAuthors: Mahantesh M Ganganallimath, Dr. K. Vizayakumar, Dr. Umesh M Bhushi
Abstract: By providing cast components to the automotive, aerospace, agriculture, and heavy engineering industries, the Indian foundry sector is vital to the manufacturing ecosystem. Operational efficiency is nevertheless impacted by enduring problems such casting flaws, high rejection rates, process unpredictability, and lengthy lead times. The Six Sigma methodology and 3D printing (additive manufacturing) have become two of the most promising approaches for quality optimization in recent years. A comparative analysis of these approaches in the context of Indian foundry operations is presented in this research. Six Sigma gives a systematic statistical foundation for defect reduction and process control through DMAIC, while 3D printing allows quick prototyping, intricate mold/core manufacturing, and shorter design-to-production times. The study contrasts the two strategies based on factors like productivity, long-term sustainability, cost, implementation time, and defect reduction. According to the results, a hybrid strategy that combines Six Sigma with 3D printing produces better quality results and gives Indian foundries a competitive edge.
DOI: https://doi.org/10.5281/zenodo.19813109
