DESIGN OF A COMBINED TUBE FEEDING AND CUTTING MECHANISM USING DESIGN FOR SIX SIGMA APPROACH

Document Type : Original Article

Authors

1 Associate Professor, Production Engineering and Mechanical Design Department, Faculty of Engineering, Menofia University, Shebin El-Kom, Egypt.

2 Assistant Professor, Production Engineering and Mechanical Design Department, Faculty of Engineering, Menofia University, Shebin El-Kom, Egypt.

3 Assistant professor, Mechanical Engineering Department, Faculty of Engineering (Shoubra), Benha University, Cairo, Egypt.

Abstract

ABSTRACT
Design for Six Sigma (DFSS) is a proactive approach that aims at designing in
quality during the early stages of product or process development. In this paper, the
DMADV (Define-Measure-Analyze-Design-Verify) methodology has been applied to
an industrial process. The considered application involves cutting tubes to
predefined lengths in order to be supplied to custom-made automotive exhaust tube
manufacturers. Investigating the process reveals several problems that adversely
affect the production. Accordingly, customer requirements have been identified and
the Quality Function Deployment (QFD) has been implemented to translate these
requirements into technical characteristics. A conceptual design of a compound
mechanism for both feeding and cutting has been suggested to overcome the
drawbacks in the current practice. A detailed 3D CAD model has been developed, in
addition to a prototype that has been manufactured to test the validity of the
proposed design. Pilot runs of the prototype reveal that the developed mechanism
not only performs its intended task adequately, but also the chances of cutting wrong
tube lengths have been eliminated.

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