Six Sigma Application In Polyurethane Foam Industry For Defective Headrests Case Study

Pages: 7 (1522 words) Published: February 22, 2017


Six sigma application in Polyurethane Foam Industry for defective Headrests.
C.E 2.1 – Introduction:
During my penultimate year of my engineering in Delhi Technological University, as a part of the academic curricula, I had to work in a scientific setting ,and prepare and present a report on my learnings to the faculty member incharge. I had choosen to do a research project in Flexo Foams private limited. This project prepared me for the role of a production engineer.
Chronology: From Decemeber 12,2013 - to December 26,2013
The geographical location of the workplace: Haryana,India
Company Name: Flexo Foams Private Limited
The title of the position occupied: Engineering Intern
C.E 2.2 - Background
I worked in the polyurethane foam department...

b) Reduce Moisture Regain below 25% without compromising the mechanical strength of the final cast. For this decreasing the number of voids in the final cast to one or nil is required.

Within this phase, the process map of the entire process was developed.

C.E 2.11 – Measure:
Then a cause and effect diagram was used, which is a tool that shows systematic relationship between the effect and its possible causes.

The possible number of defects and their causes were summarized by brainstorming with the supervisor and operators. The major types of defects could be categorized systematically as:
a) Type of voids:
1. Large voids 2. Small voids/Blow holes
b) Poor Surface Quality due to:
1. Streaking 2. Blistering
3. Sink/Shrink marks 4. Loose skin



C.E 2.12 –...

Mold Release Agent Issues- I advised the supervisor to not use water based mold release as it may cause bubbles in the surface .A very hot mold diminishes the effect of the mold release. Maintain control of mold temperature first. More release agent must be sprayed if part’s loose skin prevails or cut back the amount if voids are seen, a balance must be maintained.

5. Improper Flow Rate- Increasing flow rate for longer wait times .By use of lower viscosity polyurethane to increase the flow or temperature of the mixture could be increased.

6. Lack of Venting (Back pressure due to unvented air traps can cause a void)- Eliminate air traps by thorough cleaning of all the vents, all eight vents in this case. Before unclamping mold vents can be cleaned to save time and energy.

7. Short Cycle Time - The operator may not understand the importance of maintaining consistent cycles, so instruction is a must. Moreover, the mold should be opened 2-3 minutes later than usual time.

8. Poor Housekeeping - Daily 10 minutes session of work area cleaning prior to molding/mixing and removing unnecessary obstructions in movements for smooth...
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