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jornal article, 2023
ABSTRACT The hot-dip batch galvanization (HDBG) process is one of the most popular and widely us... more ABSTRACT
The hot-dip batch galvanization (HDBG) process is one of the most popular and widely used
techniques of galvanization and a prime consumer of 50% of zinc produced annually. An increase
in production expenses due to excess zinc and energy consumption is a major problem in the
HDBG process of many galvanizing industries. To identify the root cause of zinc and energy
consumption and improve the process, a case study is presented in the HDBG process of Gatepro
steel p.l.c tower parts manufacturing industry. Six Sigma’s DMAIC approach is implemented in
the HDBG process of this industry and investigated that the over-coating of zinc layer is the major
cause of excess zinc and energy exploitation. The 2
3
factorial model of the design-of-experiments
(DOE) is adopted in the improve phase of DMAIC, which established the relation between coating
thickness and its influencing factors. The ANOVA confirmed that immersion time and silicon
present in steel material significantly impact the coating thickness. The immersion time of 3 min
has been determined to result in optimum coating thickness. By setting immersion time up to a
standard level, an improvement in the HDBG process has been achieved. Due to this, the process
sigma level is improved from -1.5 to 3, and now 99.73% of products are within the acceptable
range of coating thickness. These outcomes have proven that the Six Sigma implementation
together with DOE enhances the product quality and improves the process, which helps industry
to achieve sustainable competitive benefits. Also, the findings of the questionnaire yielded a grand
mean of low range for training and development and communication except for supply and
availability of raw-materials, tools & machine accessories and training and development which
fall under medium range. This implied that even if there are several areas concerning all the
independent variables which needs improvement by the company communication as well as
training and development are especially found to be more attention and effort requiring areas. Not
also on this, but also on supply and availability of raw-materials, tools & machine accessories and
training and development require little
Keywords: DMAIC · 2
3
factorial design · Zinc over-coating · Hot-dip batch galvanization ·
Process capability
jornal article, 2023
The hot-dip batch galvanization (HDBG) process is one of the most popular and widely used techni... more The hot-dip batch galvanization (HDBG) process is one of the most popular and widely used
techniques of galvanization and a prime consumer of 50% of zinc produced annually. An increase
in production expenses due to excess zinc and energy consumption is a major problem in the
HDBG process of many galvanizing industries. To identify the root cause of zinc and energy
consumption and improve the process, a case study is presented in the HDBG process of Gatepro
steel p.l.c tower parts manufacturing industry. Six Sigma’s DMAIC approach is implemented in
the HDBG process of this industry and investigated that the over-coating of zinc layer is the major
cause of excess zinc and energy exploitation. The 2
3
factorial model of the design-of-experiments
(DOE) is adopted in the improve phase of DMAIC, which established the relation between coating
thickness and its influencing factors. The ANOVA confirmed that immersion time and silicon
present in steel material significantly impact the coating thickness. The immersion time of 3 min
has been determined to result in optimum coating thickness. By setting immersion time up to a
standard level, an improvement in the HDBG process has been achieved. Due to this, the process
sigma level is improved from -1.5 to 3, and now 99.73% of products are within the acceptable
range of coating thickness. These outcomes have proven that the Six Sigma implementation
together with DOE enhances the product quality and improves the process, which helps industry
to achieve sustainable competitive benefits. Also, the findings of the questionnaire yielded a grand
mean of low range for training and development and communication except for supply and
availability of raw-materials, tools & machine accessories and training and development which
fall under medium range. This implied that even if there are several areas concerning all the
independent variables which needs improvement by the company communication as well as
training and development are especially found to be more attention and effort requiring areas. Not
also on this, but also on supply and availability of raw-materials, tools & machine accessories and
training and development require little
Keywords: DMAIC · 2
3
factorial design · Zinc over-coating · Hot-dip batch galvanization ·
Process capability
jornal article, 2023
ABSTRACT The hot-dip batch galvanization (HDBG) process is one of the most popular and widely us... more ABSTRACT
The hot-dip batch galvanization (HDBG) process is one of the most popular and widely used
techniques of galvanization and a prime consumer of 50% of zinc produced annually. An increase
in production expenses due to excess zinc and energy consumption is a major problem in the
HDBG process of many galvanizing industries. To identify the root cause of zinc and energy
consumption and improve the process, a case study is presented in the HDBG process of Gatepro
steel p.l.c tower parts manufacturing industry. Six Sigma’s DMAIC approach is implemented in
the HDBG process of this industry and investigated that the over-coating of zinc layer is the major
cause of excess zinc and energy exploitation. The 2
3
factorial model of the design-of-experiments
(DOE) is adopted in the improve phase of DMAIC, which established the relation between coating
thickness and its influencing factors. The ANOVA confirmed that immersion time and silicon
present in steel material significantly impact the coating thickness. The immersion time of 3 min
has been determined to result in optimum coating thickness. By setting immersion time up to a
standard level, an improvement in the HDBG process has been achieved. Due to this, the process
sigma level is improved from -1.5 to 3, and now 99.73% of products are within the acceptable
range of coating thickness. These outcomes have proven that the Six Sigma implementation
together with DOE enhances the product quality and improves the process, which helps industry
to achieve sustainable competitive benefits. Also, the findings of the questionnaire yielded a grand
mean of low range for training and development and communication except for supply and
availability of raw-materials, tools & machine accessories and training and development which
fall under medium range. This implied that even if there are several areas concerning all the
independent variables which needs improvement by the company communication as well as
training and development are especially found to be more attention and effort requiring areas. Not
also on this, but also on supply and availability of raw-materials, tools & machine accessories and
training and development require little
Keywords: DMAIC · 2
3
factorial design · Zinc over-coating · Hot-dip batch galvanization ·
Process capability
jornal article, 2023
The hot-dip batch galvanization (HDBG) process is one of the most popular and widely used techni... more The hot-dip batch galvanization (HDBG) process is one of the most popular and widely used
techniques of galvanization and a prime consumer of 50% of zinc produced annually. An increase
in production expenses due to excess zinc and energy consumption is a major problem in the
HDBG process of many galvanizing industries. To identify the root cause of zinc and energy
consumption and improve the process, a case study is presented in the HDBG process of Gatepro
steel p.l.c tower parts manufacturing industry. Six Sigma’s DMAIC approach is implemented in
the HDBG process of this industry and investigated that the over-coating of zinc layer is the major
cause of excess zinc and energy exploitation. The 2
3
factorial model of the design-of-experiments
(DOE) is adopted in the improve phase of DMAIC, which established the relation between coating
thickness and its influencing factors. The ANOVA confirmed that immersion time and silicon
present in steel material significantly impact the coating thickness. The immersion time of 3 min
has been determined to result in optimum coating thickness. By setting immersion time up to a
standard level, an improvement in the HDBG process has been achieved. Due to this, the process
sigma level is improved from -1.5 to 3, and now 99.73% of products are within the acceptable
range of coating thickness. These outcomes have proven that the Six Sigma implementation
together with DOE enhances the product quality and improves the process, which helps industry
to achieve sustainable competitive benefits. Also, the findings of the questionnaire yielded a grand
mean of low range for training and development and communication except for supply and
availability of raw-materials, tools & machine accessories and training and development which
fall under medium range. This implied that even if there are several areas concerning all the
independent variables which needs improvement by the company communication as well as
training and development are especially found to be more attention and effort requiring areas. Not
also on this, but also on supply and availability of raw-materials, tools & machine accessories and
training and development require little
Keywords: DMAIC · 2
3
factorial design · Zinc over-coating · Hot-dip batch galvanization ·
Process capability