92

CHAPTER 5

APPLICATION STUDY OF TOTAL SIX SIGMA FUNCTION

DEPLOYMENT IN WELDING ELECTRODE
MANUFACTURING PROCESS

5.1 INTRODUCTION

The second application study on TSSFD was conducted in a

company in which mild steel welding electrodes are manufactured. Although
numerous welding techniques are adopted currently, because of its easiness
and economic usage, still arc welding is largely used for joining similar
metals (particularly ferrous based metals). Many researches have been
conducted on arc welding. However, it appears that no researcher has
conducted studies on improving the manufacturability of the coated welding
electrode which is the core component of arc welding. Considering this
research gap, the application study being reported in this chapter was carried
out. During this application study, the TSSFD technique was applied on the
coated welding electrode manufacturing process. The details of the activities
carried out during this application study are presented in this chapter.

5.2 BACKGROUND OF R.K.

It is essential that the readers are able to recognize the working

atmosphere amidst which the application study on TSSFD was conducted in a
welding electrode manufacturing company. Hence, the background of this
company is briefly described here. The name of this company is
R.K.Electrodes (hereafter referred to as R.K.). R.K. is situated in Coimbatore
 93

city of India. R.K. was started in the year 2001. At the time of starting, 21
employees were working. Currently 40 employees are working in R.K. At the
time of inception, the turnover of R.K was 54 lakhs in Indian National Rupees
(INR) (equivalent to 108, 00 U.S dollars). Thus R.K has grown gradually over
the past seven years. At the time of starting, only mild steel welding
electrodes were manufactured at R.K. Currently welding electrodes used for
special purposes are also being manufactured at R.K. The welding electrodes
manufactured by R.K are sold mainly in Tamilnadu state of India. Some
volumes of welding electrodes manufactured are sold in neighboring states of
Tamilnadu namely Andhrapradesh, Kerala and Karnataka.

Out of the 40 employees, four of them occupy managerial

positions. Remaining employees occupy non-managerial positions. Since the
management does not aspire to enter into the international market, no
competitive strategies and models like TQM, TPM and ISO 9000 certification
are implemented in R.K. However, even in the absence of ISO 9000
certification, well defined quality system without much documentation is
being operated at R.K. In spite of not implementing any competitive strategies
and models, the management of R.K. was generous to allow the conduct of
the application study of TSSFD in its premises.

5.3 WELDING ELECTRODE MANUFACTURING PROCESS

The manufacturing of welding electrode is described in this section

as it is not widely documented in literature. This will enable the readers to
appreciate the essence of applying TSSFD technique in the welding electrode
manufacturing process. Welding is one of the widely researched and practiced
engineering activities. Welding is the process of joining two parts with or
without the application of heat and pressure. Over the years, numerous types
of welding techniques have been brought out by the researchers and
 94

practitioners. Each welding technique is suited for joining two parts under
specific environments, conditions and circumstances. The cost of welding is
also varied with respect to different techniques (Jeffus 1999).

Despite the emergence of highly advanced and improved welding

techniques, electric arc welding has still been finding wide applications
throughout the world. In this technique, heat is produced by making the
metals to be joined to contact between two terminals of the electrical supply
(Cary 1995). One end is connected to a consumable welding electrode. The
other end is connected to a part to be welded. The parameters like voltage and
amperage of the current and skill of the welder play crucial roles in ensuring
good quality of the welded joints. Welding electrode is made up of special
quality mild steel. These electrodes are coated using several chemical
powders like rutile, mica, calcite (rough), calcite (fine), illuminate (rough),
illuminate (fine), china clay, felsper, cellulose, low carbon manganese, surka
jelly, titanium, iron powder, and silicate oil (Radhakrishnan 2005).

Besides playing role in joining two metals with high strength,

electric arc welding process is required to ensure comfortable working
condition to the welder. A poor quality and defective welding electrode will
create excessive smoke and spattering of the particles which will cause
injuries and discomfort to the welders (Jeffus 1999). Even though the
welding electrode plays such crucial roles, its quality is not much subjected to
research (Source: http://en.wikipedia.org/wiki/Arc_welding). In this
background, while beginning the implementation study on TSSFD, thorough
search for locating the documented articles describing the steps followed to
manufacture welding electrodes was made. This search yielded only one
result. This result indicated the availability of patterned documentation
on welding electrode manufacturing. It appears that no research
on manufacturing welding electrodes has so far been carried
 95

out. This is despite the fact that the parameters of welding electrodes
are standardized by International organizations for standardization
(ISO) and are made available in its standard ISOE432R21
(http://members.fortunecity.com/dwekam/mse.htm/). In this background, the
process adopted at R.K to manufacture the welding electrodes is presented
here to compensate the poor documentation observed in literature.

The welding electrode manufacturing process adopted at R.K. is

pictorially depicted in Figure 5.1. As shown, the manufacturing of welding
electrodes begins parallelly from three directions. In the first direction, the
raw material in the form of metal wire is drawn through a die. This process is
known as wire drawing. The purpose of this process is to get the metal wire in
the required uniform diameter. Then the drawn wire is cut into the required
lengths. At this stage, the wire becomes a number of rods. These rods have to
be fed into extruder machine through its hopper. The hopper is positioned
appropriately and pushed into the extruder. In the second parallel process, the
binder required for binding the flux with the rods is prepared. In order to mix
the binders, the process known as dosing is carried out.

In the third parallel process, dry flux powder is prepared. The dosed
binders and dry flux powder are mixed with silicate oil and sufficient quantity
of water. This mixture is known as wet powder mix. The wet powder mix is
subjected to briquitting process. During this process, the wet powder mix is
pressurized to look like a cake. This cake like flux and binder mix is fed into
the extruder along with the rods. During extrusion, the mix is impregnated on
the rods. At this stage, rods become welding electrodes. Subsequently the
welding electrodes are passed through the printers. During this process, the
code number of the welding electrode and name of the company are printed
on the welding electrodes. At this stage, the welding electrodes are inspected.
 96

Wire Drawing Binders Raw materials

Dry flux
Dosing preparation
Wire Cutting

Wet flux preparation

Loading rods in
the hopper Briquetting

Wire washing Extrusion of rods

Printing

Rejection Concentricity testing

recovery and visual inspection

Baking

Rejection
recovery Visual inspection

Packing Storing

Figure 5.1 Welding electrode manufacturing sequence

A number of sophisticated techniques and methods are available to

inspect welding electrodes. However, as they are expensive, only the visual
inspection is adopted at R.K. During visual inspection, the welding electrodes
are inspected to check three quality parameters namely concentricity of
 97

electrode, mixture proportion and crack in the coating. The welding electrodes
passing successfully the inspection stage are subjected to baking process.
During this process, the welding electrodes are baked to increase their
hardness.

The welding electrodes failing in the inspection process are

subjected to recovery. During the recovery process, the welding electrodes are
subjected to wire washing. During this process, the mixture coated around the
welding electrode is removed. The baked welding electrodes are again
inspected. During this inspection process, a sample consisting of few welding
electrodes are tested to check for defects, such as spattering, smoke
emanation, cracking, slag removal, non-uniform welding and withstanding of
properties at high temperature of welding. The welding electrodes failing at
this stage of inspection are rejected. Only the welding electrodes with minor
defects are subjected to recovery process.

Thus the welding electrodes which are the backbones of arc

welding process are manufactured in large volumes through intricate stages
requiring careful timing and mixing of binders and flux, and coating them on
the metal wire. Although various parameters determine the quality of the
welding electrode, the most common reasons against which customers express
dissatisfaction against the welding electrodes are, smoke emanation during the
welding process, spatter and cracks in the weldments.

5.4 APPLICATION STUDY

After gaining knowledge about the manufacturing process of

welding electrode, the application study of TSSFD was begun at R.K. The
details of this study are briefly presented in the following subsections.
 98

5.4.1 Customer requirement matrix

As mentioned in chapter 3, the beginning of TSSFD is marked by

the development of customer requirement matrix. In order to develop the
customer requirement matrix, during this application study, the first author
traveled little more than 500 kilometers to approach as many as 200
customers and received their complaints about the welding electrodes
supplied by the R.K. During this exercise, the dealers of R.K. and employees
of service department also indicated complaints expressed by the customers.
After recording those complaints, they were consolidated. This consolidation
revealed that five complaints are frequently made by the customers of R.K.
Those complaints were entered in the customer requirement matrix. This
completed customer requirement matrix is shown in Table 5.1.

As shown, each customer voice is given a TSSFD number. Though

orally many customer complaints were gathered, some of them were
communicated via letters, email and telephone. Those details are presented
under nodes and channels columns of customer requirement matrix. These
details were shown to two personnel possessing knowledge on welding
electrode manufacturing. The first personnel was a formally educated welding
engineer. The second personnel was an expert in welding possessing 30 years
of practical experience but possessing no formal education. The former
possessed higher theoretical knowledge on welding than the latter and the
latter possessed higher practical knowledge on welding than the former. Thus
attempts were made to conglomerate the theory and practice of welding
electrode manufacturing. These two personnel were requested to indicate the
importance ratings against each customer voice in the customer requirement
matrix. The ratings specified by them are shown in Table 5.1.
 99

Table 5.1 Customer Requirement Matrix

Ratings in a Likerts

Scope of the Project

scale of range 0-10
TSSFD Number

Customer Voice

Importance
Channels
Nodes
1 Crack Dealers/ Letters/ 7 TSSFD3 is
observed in Customer/ E-Mail/ chosen now.
work piece Service Oral/ TSSFD3
(after welding) personnel Telephone project will be
applied on the
2 Excessive following
spatter during 7 processes.
welding
a) Wet
3 Excessive powder
smoke 9 mixing
observed b) Extrusion
during welding c) Baking

4 Taper welding 6

5 Slag is not
removed 6
instantaneously
during welding

As shown in Table 5.1, excessive smoke observed during welding

was found to be the most important customer voice as this was assigned an
importance rating of 9 by the above two personnel. This was followed by the
two customer voices namely Crack observed in work piece (after welding)
and Excessive spatter during welding which were given the rating 7. In this
background, excessive smoke observed during welding, was considered
 100

during subsequent stages of TSSFD implementation study. This customer

voice was also given the code TSSFD3.
The author of this thesis availed the expertise of little more than 10
welding electrode manufacturing experts to carry out the preliminary analysis
for translating TSSFD3 into technical languages. After the end of this
consultation, the author of this thesis realized that, the TSSFD3 shall involve
three processes of welding electrode manufacturing namely wet powder
mixing, extrusion and baking. These were finally entered as the scope of the
project in the customer requirement matrix. With this, the development of
customer requirement matrix was completed at R.K.

5.4.2 Define phase

The define phase of TSSFD application study was begun by

developing the project charter. The project charter of TSSFD3 developed
during this application study is shown in Table 5.2.

As shown in Table 5.2, the first input of the TSSFD project charter
is scope of the project. This is derived from customer requirement matrix.
Subsequently, the problem of TSSFD3 is defined. From 20 to 25 percentages
of customers complain that excessive smoke is billowed during welding. Most
of the remaining 70-75 percentage of customers are highly experienced and
hence, use several control methods like regulating the amperage and voltage
of the current, and wearing protective devices to escape from the smoke.
Other details like the project duration and members of TSSFD are also
specified in the project charter. Finally the enhancement of customer
goodwill was identified as one of the expected gains.
 101

Table 5.2 Project Charter of TSSFD 3

20-25 percentages of customers complain that excessive

Problem smoke is observed during welding. Excessive smoke causes
Description eye irritation to the welders which lead to the stoppage of
welding process.
Scope of the Project will be applied on the following processes.
Project A. Wet powder mixing B. Extrusion C. Baking
Project will not concentrate on the following processes:
Excluded Scope
1.Wire drawing 2.Dry powder mixing 3.Briquetting
of the Project
4.Packing
All the types of welding electrode manufactured in R.K.
Target
will not billow excessive smoke.
Define Phase : 20 days
Measure Phase : 15 days
Project Duration Analyze Phase : 20 days
Improve Phase : 25 days
Control Phase : 20 days
Participating functions and members:-
Expert : Dr.S.R.Devadasan
Coordinator : Mr.V.Thirunavukkarasu
Sponsor : Mr.R.Kandasamy
Functions Members TSSFD designation
Wet powder mixing Mr.M.Sathya Raj Green Belt
Extrusion Mr.M.Sathya Raj Green Belt
Mr.S.Gopal Green Belt
Baking
Mr.K.Sasi Green Belt
Inspection (Sample testing) Mr.R.Raman Green Belt
Marketing Mr.V.Ramalingam Green Belt
Administration Mr.T.R.K.Prabhu Black Belt
Resources Required:
Facilities for training the operators
Facilities for conducting continuous quality improvement activities
Expected gains:
Least number of customer complaints on billowing of excessive
smoke during welding.
Enhancement of customer goodwill on R.K.
 102

Table 5.3 SIP Cross-study sheet

TSSFD3
Process :Wet powder mixing
Responsible
Supplier Process Cross-functions
officers
Extrusion,
External Wet powder Mr. M.Sathya Raj
Baking and
suppliers mixing Mr.R.Raman
Inspection
Process : Extrusion
Responsible
Supplier Process Cross-functions
officers
Wet powder
Baking and Mr. M. Sathya Raj
mixing (internal Extrusion
Inspection Mr.R.Raman
supplier)
Process : Baking
Responsible
Supplier Process Cross-functions
officers
Extrusion and Mr.S.Gopal
Extrusion Baking
Inspection Mr.K.Sasi
Process : Inspection
Responsible
Supplier Process Cross-functions
officers
Extrusion and
Baking Inspection Mr.R.Raman
Baking

After developing the TSSFD project charter, SIP Cross-study sheet

was developed through the identification of the networking processes and
functions. As indicated in customer requirement matrix and project charter,
the three functions namely wet powder mixing, extrusion and baking were
found to play crucial roles in reacting to the TSSFD3. With the involvement
of the TSSFD3 members, the SIP Cross-study sheet shown in Table 5.3 was
developed. Besides inspection was also included as a function since it was
found to tightly associate with the above three functions.
 103

Marketing function was not considered because the role of

marketing ends by communicating the customer voices to the TSSFD3 team.
As shown in Table 5.3, the development of SIP Cross-study sheet was useful
in identifying the officers responsible for carrying out the inspection and other
three functions which were found to fall within the scope of TSSFD3.

5.4.3 Cross-functional matrix

The TSSFD members subsequently discussed to identify the

importance of the roles played by four functions. After establishing the
importance ratings in a Likerts scale of range 0-10, the same were posted in
the cross-functional matrix. The cross-functional matrix thus developed for
TSSFD3 at R.K. is shown in Table 5.4. As shown, wet powder mixing plays
the most important role with the importance rating of 9. While the inspection
plays least important role with the importance rating of 5.

Table 5.4 Cross-functional matrix

TSSFD 3
Functional /departmental importance
rating
Customer Importance
Wet Remarks
voice rating
powder Extrusion Baking Inspection
mixing
Excessive
smoke
billowed 9 9 7 8 5
during
welding
 104

5.4.4 Measure phase

In order to estimate the degree of improvement to be achieved, the

sigma level at which the R.K. operated had to be determined. Though well
defined system of recording customer complaints is not prevailing at R.K.,
informal way of noting down the customer complaints is practiced. This
informal way is marked by writing down the customer complaints in note
books. The relevant data were gathered from these note books and the sigma
level at which R.K. was operating was computed. The details of this
computation are shown in Table 5.5.

Table 5.5 Computation of overall Sigma level

5,000 packing cases (Each packing case

Annual Production contains16 boxes. 90 welding
electrodes are packed in each box)
Monthly Production 400-425 packing cases
Total number of packing cases
against which complaints are 50-55 packing cases/ month
received due to TSSFD3
Percentage of defectives per
12.5 to 12.95%
month due to the TSSFD3
DPMO
Overall Sigma Level
2.655

As shown, the DPMO was found to be 124,750. The sigma level

against this DPMO is 2.655. The reason for R.K. operating at less than even
three sigma level is attributed to the fact that formal quality control techniques
like statistical process control, statistical quality control etc. are not applied
systematically at R.K. This is also due to the reason that, formal studies on
applying quality control, TQM tools and techniques in welding electrode
manufacturing are yet to occur in both researching and practicing arenas.
 105

Further, the sigma level computations were carried out with respect
to four functions. Those computations are shown in Table 5.6. As shown, the
baking process is operated at highest sigma level with the value of 3.291.
Inspection is done at a least sigma level of 2.345. As shown in Table 5.6, wet
powder mixing and baking are operated at higher than the 3 sigma level
indicating the higher importance shown on this process at R.K.

Table 5.6 Sigma level computations

Opportunity

Opportunity
Component/

(number of
Defectives
Process

DPMO
type of
defect)

Sigma
Level
Total

DPO
DPU
Unit

Wet
powder 2 30 1 30 0.0666 0.0666 66,666 3.01
mixing
Extrusion 3 30 1 30 0.100 0.100 100,000 2.85
Baking 2 30 2 60 0.0166 0.0333 33,333 3.291
Inspection 6 30 1 30 0.2000 0.2000 2,00,000 2.345
Average Sigma = 2.874

The smaller sigma level of inspection indicates the need of

strengthening inspection function. The average sigma level was found to be
2.874. This value is slightly higher than overall sigma level. This slight
difference with average sigma level indicated the weak integration of
inspection with the other functions identified in TSSFD3 project.

5.4.5 Product deployment matrix

At this stage of TSSFD3 application study, the personnel associated

with the four functions underwent three brainstorming sessions to identify the
final process characteristics that would have to be considered while reacting
to the TSSFD3. The final product deployment matrices developed at the end
 106

of these brainstorming sessions by these personnel are shown in Tables 5.7-

5.10. As shown, the importance of the final product characteristics was also
estimated by these personnel using the Likert scale of range 0-10.

As a sample, product deployment matrix pertaining to the wet

powder mixing process is illustrated here. As shown, in Table 5.7, the
employee associated with wet powder mixing process expressed the view that
moisture during briquette formation and mixing preparation was found to play
crucial roles in reacting to TSSFD3. The purpose of listing the integrating
functions with their sigma levels is to indicate the degree of improvement
expected from those functions to achieve the targets mentioned in TSSFD3
project charter.

Table 5.7 Product deployment matrix - Wet powder mixing processes.

TSSFD3
Final process characteristics Process/ Sigma
Function/ 1 2 3 Function Level
process Briquette Mixing
Moisture Extrusion 2.85
formation proportion
Wet powder Baking 3.291
8 6 9
mixing Inspection 2.345

Table 5.8 Product deployment matrix - Extrusion

TSSFD 3
Final process characteristics Process/ Sigma
Function Level
1 2 3
Function/
process Fixing of Size variation in 3.291
die in Adhesion the internal Baking
machine diameter of die
Extrusion 7 7 7 Inspection 2.345
 107

Table 5.9 Product deployment matrix - Baking

TSSFD 3
Final process characteristics Process/ Sigma
Function Level
Function/ 1 2 3
process Heating
Natural Electrical power
in the Extrusion 2.85
air drying interruption
oven
Baking 5 7 6 Inspection 2.345

Table 5.10 Product deployment matrix - Inspection

TSSFD 3
Final process characteristics Process/ Sigma
1 2 3 Function Level
Function/
process Wet
Sampling Adequate
Judgment powder 3.01
size observation
mixing
Baking 3.291
Inspection 6 8 4
Extrusion 2.85

5.4.6 Analyze

During the analyze phase, the two tools namely Cause and Effect
diagram and why-why analysis are employed. Since TSSFD3 members at
R.K. lacked knowledge on TQM tools, the author of this thesis had to draw
the format of cause and effect diagram and gather the necessary information
and knowledge. For this purpose, during this stage of application study, all the
TSSFD3 members assembled and analyzed to bring out the information and
knowledge on the causes and effects pertaining to TSSFD3. Those
information and knowledge were substituted by the first author to develop the
cause and effect diagram shown in Figure 5.2. As shown, the problem of
 108

TSSFD3 is the final effect while causes are entered under four functions.
Further, the causes were given code numbers C1, C2, C3 etc. As shown,
totally 14 causes were identified.

After developing cause and effect diagram against each cause,

why-why analysis was conducted with the participation of TSSFD3 members.
The responses gathered against the why-why questions against each cause are
shown in Table 5.11. As a sample, the why-why analysis pertaining to the
cause C1 is illustrated here. As shown, the reason for breaking of flux coating
during welding processes is analyzed using the two why questions. The
answer for the second question enables the analyzer to understand that
improper instruction and training are main reasons for the breaking of flux
coating during welding processes. Thus why-why analysis was conducted for
all the 14 causes identified in cause and effect diagram to identify the main
reasons.

Table 5.11 Why-why analysis.

C1. 1. Why is flux coating broken during welding process?

Mixing proportion is not correct. Moisture level is maintained either high or
low during wet powder mixing process.
2. Why do mistakes namely incorrect mixing proportion and maintenance of
incorrect moisture level occurs?
Operators are not properly instructed and trained to the required extent for
mixing correct proportion of powder and silicate oil.
C2. 1. Why does crack form during extrusion process?
The flux is kept either too wet or dry.
2. Why is flux kept either wet or dry?
Moisture level is not checked using any instrument during the entire wet
powder mixing process.
 109

Table 5.11 (Continued)

C3. 1. Why is the powder not mixed properly while making the coating?
Proportion is not correctly maintained during the wet powder mixing
Process.
2. Why the proportion not correctly maintained during wet grinding process?
Operators are not trained to mix the wet powder.
C4. 1. Why does porosity occur during welding process due to improper mixing of
powders?
The low carbon manganese weight is not checked before mixing.
2. Why is the weight of low carbon manganese not checked before mixing?
Operators are not formally and sufficiently trained to check the weight of low
carbon manganese before mixing.
C5. 1. Why is the slag not getting removed instantaneously during welding due to
improper mixing of powder?
Inadequate quantity of rutile powder is mixed.
2. Why inadequate quantity of rutile powder is mixed during wet powder
mixing?
Operators are not formally instructed and trained to check the weight of
rutile powder before mixing the powder.
C6. 1. Why is the coating thickness varied during extrusion process?
Either the die is worn out or die is not properly fixed in the extrusion
machine.
2. Why is the condition of die not checked before starting the extrusion
machine?
The system of checking the die condition does not exist due to the high
cost and difficulty involved.
C7. 1. Why does the eccentricity of coating occur leading to one side welding?
Die conditions like wear and tear, adjustment in fixing, existence of foreign
particles etc. are not checked.
2. Why is the die conditions not checked before starting of extrusion
process?
The system of checking the die condition does not exist due to the high
cost and difficulty involved.
 110

Table 5.11 (Continued)

C8. 1. Why does the eccentricity of electrode occur leading to taper welding?
Die conditions like wear and tear, fixture location, and existence of foreign
particles etc. are not checked.
2. Why are the die conditions not checked before starting of extrusion
process?
The system of checking the die condition does not exist due to the high
cost and difficulty involved.
C9.1. Why is natural drying not carried out during baking process?
At the end of the days work, time is found inadequate to carry out
natural drying during the baking process.
2. Why the time found inadequate at the end of the day to carry out
natural drying during the baking process?
Absence of planning and scheduling the jobs prevents the natural drying
during baking process.
C10. 1. Why the furnace improperly heated?
Automatic control system is not used.
2. Why is the automatic control system not used?
Despites its availability, operators are not possessing the required skill to
use automatic control system for supplying correct heat inside the furnace.
C11. 1. Why is the electric supply interrupted?
Electricity supplied by the Government is often disruptive.
2. Why is the electric power supply not restored soon after its disruption?
Electricity generator is not available to restore electric power supply.
C12. 1. Why the smoke level not checked using an instrument during inspection
function?
High time consumption and cost of the smoke level measurement
instrument prevent the smoke level measurement.
2. Why are the alternative actions not taken to overcome the problems of
high time consumption and cost of smoke level measurement instrument?
Both management and employees believe that these problems cannot be
practically overcome.
 111

Table 5.11 (Continued)

C13. 1. Why is the excessive spatter not checked while welding?

No systematic procedure is available to check the excessive spatter.
2. Why is a systematic procedure not available to check excessive spatter?
Production is affected in case of systematic procedure is adopted to check
the excessive spatter.
C14. 1. Why is the crack not checked by welding different steel alloys?
No systematic procedure is available to check the welding parts made of
different steel alloys.
2. Why is a systematic procedure not available to check cracks by welding of
parts made of different alloy steels?
Production will be affected as a systematic procedure would require the
employment of an inspector to vary different parameters and sample pieces
f checking the effect of welding parts made of different steel alloys.

5.4.7 Improve phase

During the improve phase, the author of this thesis consulted the
TSSFD3 members and developed the cause and reason matrix shown in Table
5.12. As shown, the outputs of cause and effect diagram and the why-why
analysis were the inputs of cause and reason matrix of TSSFD3.

The cause numbers and causes indicated in cause and effect

diagram were entered in first and second columns respectively of cause and
reason matrix. In the third column, the reason for the occurrence of each
cause identified during the conduct of why-why analysis was entered. In the
fourth column, the actions required to overcome the causes were entered.
These actions were prepared by the author of this thesis in consultation with
TSSFD3 members.
 Wet powder mixing Extrusion
C4. Porosity in
C1. Flux coating is welding process
broken while welding due to improper
mixing of powder C6. Varying of C8. Eccentricity of
coating thickness coating leading to
C2. Crack formed in
rod during extrusion C5.Due to taper welding
process improper mixing,
C3. Improper mixing of slag is not removed C7. Eccentricity of
powder while making instantaneously coating leading to
the coating one side welding
Excessive
smoke
observed
C12. Not checking
smoke level using
during welding
C11. Power C13. Not
interruption spoils instruments
checking excessive
C9. Natural drying is temperature uniformity spatter while welding
not done
C14. Crack is not checked by
welding parts made of different
C10. Furnace is
grade of steel alloys.
improperly heated.

Baking Inspection

Figure 5.2 Cause and Effect diagram of TSSFD3

2
11
 Table 5.12 Cause and Reason Matrix

Cause Action required to Additional cost to be Defects/

Cause Reason
Number overcome the causes expended per day Customer returns

1 Flux coating is broken
while welding.
Mixing of powders results in either Operators may be trained No additional Defect will be
excessive or low moisture content to check the moisture expenditure will be reduced to
in welding electrodes. Operators are level. incurred. 9 percentages.
not instructed about the importance
of proper mixing of powders.

2 Crack formed in Mixing of powders results in either Operators may be trained No additional Defect will be
electrode during the excessive or low moisture content to check the moisture expenditure will be reduced to
extrusion function. in welding electrodes. Operators are level. incurred. 9 percentages.
not instructed about the importance
of proper mixing of powders. They
are not trained to this effect.

3 Improper mixing of Mixing of powders results in either Operators may be trained No additional Defect will be
powder while making excessive or low moisture content to check the moisture expenditure will be reduced to
the coating. in welding electrodes. Operators are level. incurred. 9 percentages.
not instructed about the importance
of proper mixing of powders. They
are not trained to this effect.

3
11
 Table 5.12 (Continued)

Cause Action required to overcome the Additional cost to be Defects/

Cause Reason
Number causes expended per day Customer returns

4 Porosity in welding No electronic weighing An electronic weighing machine to Rs.1640 is the purchase Defect will be
process due to machine is available to weigh low carbon manganese is to price of an electronic reduced to
improper mixing of check the weight of low be purchased. The operators shall weighing machine. This 9 percentages.
powder. carbon manganese. be trained to use this electronic price is negligible.
weighing machine.

5 Due to the mixing of Inadequate quantity of An electronic weighing machine to Rs.1640 is the purchase Defect will be
inadequate quantity of rutile powder is added weigh rutile powder is to be price of an electronic reduced to
rutile powder, slag is during mixing. purchased. The operators shall be weighing machine. This 9 percentage.
not removed trained to use this electronic price is negligible.
instantaneously during weighing machine.
welding process.

6 Varying of Either the die is worn out System is to be developed and No additional From 3 to 3.5
coating thickness. or die is not properly fixed implemented for envisaging expenditure will be percentage of
in the extrusion machine. operators to check condition of the incurred. reduction in
die. defects.

4
11
 Table 5.12 (Continued)

Additional cost to
Cause Action required to overcome the Defects/
Cause Reason be expended per
Number causes Customer returns
day

7 Eccentricity of Die conditions like wear and System is to be developed and No additional From 3 to 3.5
coating leading tear, adjustment in implemented for envisaging operators expenditure will be percentage of
to one side fixing, existence of foreign to check condition of the die. incurred. reduction in defects.
welding. particles etc. are not checked.

8 Eccentricity of Die conditions like wear and System is to be developed and No additional From 3 to 3.5
coating leading tear, fixture location existence of implemented for envisaging operators expenditure will percentage of
to taper welding. foreign particles etc. are not to check condition of the die. be incurred. reduction in defects.
checked.

9 Natural drying is At the end of the days work, Planning and scheduling of activities No additional cost About five
not done. time is found inadequate to carry shall be carried out everyday in the is required. percentage of
out natural drying in the baking morning so that the time is made. reduction in defects.
process.

10 Furnace is Automatic control system is not Operators are required to be trained to No additional cost About five
improperly used. use the automatic control system is incurred. percentage of
heated. already available in the machine. reduction in defects.

5
11
 Table 5.12 (Continued)

Cause Action required to Additional cost to be Defects/

Cause Reason
Number overcome the causes expended per day Customer returns

11 Power interruption Electricity generator is not Electricity may be Because a generator is used in About five
spoils temperature available to maintain purchased and installed the Managing Directors percentage of
uniformity. interruption free electric to heat only the furnace. house has been installed, no reduction in
current. additional cost is incurred in defects.
this connection.

12 Not checking smoke Both management and
level using an employees are of the view
instrument. that smoke level testing using
instrument is not practically
possible.
The service of an An operator may be asked to 0.5 to 1.0
experienced employee check the smoke level. Hence, percentage of
capable of testing the no additional expenditure is reduction in
smoke level by smelling incurred in this connection. defects
the smoke can be availed.

13 Not checking excessive No systematic procedure is A systematic procedure No additional cost is incurred. 0.5 to 1.0
spatter while welding. available to check the shall be developed to percentage of
excessive spatter. check the excessive reduction in
spatter. defects.

14 Crack is not checked No systematic procedure is A systematic procedure No additional cost is incurred. 0.5 to 1.0
on welded parts made available to check the shall be developed to percentage of
of different grades of welding of parts made of check the crack. reduction in
steel alloy. different steel alloys. defects.

6
11
 117

Subsequently, attempts were made to estimate the additional costs

to be incurred for taking the actions. Surprisingly it was found out that all the
actions required no or little expenditure for their implementation. This aspect
is coinciding with the claim of Crosby, a quality guru who has claimed that,
Quality is free (Besterfield et al 2004).

After developing cause and reason matrix, the actions were

subjected to pilot application at R.K. After that, the manufacturing of welding
electrodes was closely observed. It was found out that the number of
defectives found to be nearer to zero. The number of defectives for 480 units
produced per day was calculated with reference to the four functions. These
data are shown in Table 5.13. Subsequently the sigma levels at four functions
were computed. These details are shown in Table 5.14.

Table 5.13 Number of defects observed after TSSFD3 implementation

Number of units per

Component/Function/Process Number of defectives
day
Wet powder mixing 480 Nil
Extrusion 480 1
Baking 480 Nil
Testing/ Inspection 480 1

As shown, the average sigma level was found to be 5.58. The sigma levels
after implementation in four functions were found to increase significantly.
These comparisons of sigma levels before and after the implementation of
TSSFD3 are presented in Table 5.15.
 118

Table 5.14 Sigma level computation after implementing TSSFD3 project

types of defect)
Opportunity

opportunity
(Number of

Sigma level
Number of
defectives
Function
Product/
Process/

DPMO
Total

DPO
DPU
Unit
Wet Nil 480 Nil Nil 0 0 0 6.8
powder
mixing
Extrusion 1 480 1 480 4.36
Baking Nil 480 Nil Nil 0 0 0 6.8
Testing/ 1 480 1 480 4.36
Inspection

Table 5.15 Sigma level before and after TSSFD3 project implementation

Product/Function/ Sigma level before Sigma level after

Process TSSFD implementation TSSFD
implementation

Wet powder mixing 3.01 6.8

Extrusion 2.85 4.36
Baking 3.291 6.8
Testing/ Inspection 2.345 4.36
Average = 2.874 Average = 5.58

5.4.8 Component deployment matrix

After realizing the actions to be taken as a result of developing

cause and reason matrix, component deployment matrices pertaining to four
functions were developed. The input for preparing these component
deployment matrices were derived from the documents developed during the
 119

previous stages of the TSSFD3 project. Particularly the contents of cause

and effect diagram and cause and reason matrix were used to develop the
component deployment matrices. These matrices are shown in Table 5.16.
These matrices were useful in consolidating the actions required to be taken
for reacting against TSSFD3.

5.4.9 Process planning and control charts

The specific actions mentioned in component deployment matrices

were used to develop process planning and control charts. Besides the cause
and effect diagram and cause and reason matrix were also referred to
develop these charts. These charts are shown collectively in Table 5.17. As
shown, against each function, the planning and control strategies were
developed which were accompanied by the cause numbers. This denotion of
cause number is necessary because planning and control strategies may have
to be varied to suit different types of causes under each function.

5.4.10 Work instructions

The contents of process planning and control charts were referred

to develop the work instructions. The work instructions prepared for
implementation in four functions at R.K. are shown in Tables 5.18-5.21. As
shown, each work instruction identifies the cause numbers. There is also
provision to include the supporting documents. Operators are required to
carry out actions by referring to those documents. As shown in Tables 5.18-
5.21, the field operator is encouraged to refer to the mixing preparation
sheet/chart for identifying the proportions of the ingredients to be mixed.
Finally, the work instructions are endorsed by the competent authority. These
endorsements facilitate the field operator to execute the necessary actions for
reacting against the TSSFD3.
 Table 5.16 Component deployment matrices
TSSFD3
Component/ Finished component characteristics Design changes/ Instruction Target functions/
Function modifications Channel Department

Wet powder 1.No breakage of flux coating while welding Operators are to be trained to Work Instruction Inspection
mixing 2.No crack formation in welding electrode mix powders in correct Training Extrusion
during extrusion function proportions schedule
3.Proper mixing of powder while making Operators are to be trained to Training manual
the coating use the weighing machine to
4.No porosity in welded joints due to weigh the powders
improper mixing of powder

Extrusion 1.Uniform coating thickness as specified in A system with very focused Work Instruction Inspection
ISO 432R21 standard procedures shall be developed Training
2.No eccentricity of coating to avoid one Operators shall be trained to schedule
side welding refer to the procedures and Training manual
3. No eccentricity of coating to avoid taper apply in their work places.
welding

0
12
 Table 5.16 (Continued)
Component/ Finished component characteristics Design changes/ Instruction Target functions/
Function modifications Channel Department

Baking 1. Natural drying of all welding electrodes
for three hours
2. Proper heating of furnace
3.Maintenance of uniform temperature
Automatic control system is Work Instruction Inspection
to be used extensively
Electricity generator shall be
used to ensure supply of
electric power to heat the
furnace
Availing the service of an
experienced operator to smell
and check the smoke level.

Inspection 1.Smoke level checking Use of the service of an Work Instruction Wet powder mixing
2. Checking of excessive spatter experienced employee to Extrusion
3. Checking of cracking by welding parts smell and check the smoke baking
made of different steel alloys level.

1
12
 Table 5.17 Process planning and control charts
TSSFD3
Product/ Planning strategies Control strategies
Process/ Target function
Function 1 2 1 2

Wet powder Development of The operator, may be Make a surprise Appoint one Extrusion,
mixing: procedure and motivated to follow the surveillance on the inspector to check Baking,
instructions correct formula for extrusion operator every day whether Inspection
Cause numbers: about the maintaining exact mixing and check whether the correct mixing
C1 - C4 importance of proportion mixing of the dry formula is followed
refined wet powder and wet powders are during every batch
mixing carried out of production
appropriately
Extrusion: The operator may The extrusion operator may Check the die before Once extrusion Wet powder
be instructed for be instructed to locate the die starting the machine. process starts, mixing,
Cause numbers: checking the in appropriate position in the Instruct the operator check first 20 Baking,
C5 C7 eccentricity of the extrusion machine. The and inspectors to welding electrodes Inspection
one welding extrusion operator may be check the internal extruded
electrode for every instructed to check also the diameter of die. thoroughly for their
10 welding die internal diameter, coating thickness,
electrodes extruded existence of any foreign crack, taper and
particles and wear of the die. outer diameter.

2
12
 Table 5.17 (Continued)
Product/ Planning strategies Control strategies
Target
Process/
1 2 1 2 function
Function
Baking: Production may be It may be planned The inspector shall make The electricity Wet powder
planned before one day or for allowing a surprise visit to check generator may mixing,
Cause the supply of the electrode minimum three whether the operator be used Extrusion,
numbers: to the customer may be hours of natural makes uses of the appropriately to Inspection.
C8 C11 postponed to the next day. drying of welding automatic control system avoid the
Altogether sufficient time electrodes. appropriately by setting problem of
for baking and packing correcting baking power
may be allowed. temperature and time. interruption.
Testing/ Inspector may inspect a Inspector may Control the mixing The inspector Wet powder
Inspection sample of 20 welding inspect the smoke proportion in beginning can inspect the mixing,
Cause electrodes in a day against level and spatter by stage and thereby avoid mixing during Extrusion,
numbers: various ampere ranges. changing ampere the problems of smoke the earlier Baking.
C12 14 Inspector may be ranges from initial billowing and spattering stages and
instructed to inspect the to high levels as control those
sample welding electrodes given in the problems
from top, middle and pamphlet. arising later in
bottom trays of the the welding
furnace. electrodes.

3
12
 124

Table 5.18 Work Instruction- Wet powder mixing

TSSFD3-WI 1 of 4
Process/ Function Wet powder mixing
TSSFD document number TSSFD3 Cause Numbers: C1-C4
Target users Extrusion, Baking and Inspection
Work The operator is instructed to refer to the mixing proportion
instruction sheet/chart before start mixing the wet and dry powders.
Prepared by Sponsor, Mr.T.R.K.Prabhu.
Mr.M.Sathiyaraj, Mr.S.Gopal, Mr.K.Sasi,
TSSFD Members
Mr.R.Raman and Mr.V.Ramalingam
Proportion chart for every 100Kilograms of
Supporting documents
mix.
Endorsed by

Table 5.19 Work Instruction- Extrusion

TSSFD3-WI 2 of 4
Process/ Function Extrusion
TSSFD document number TSSFD3 Cause Numbers: C5 C7
Target users Wet powder mixing, Baking and Inspection
Highlight the importance of the extrusion process to the
Work operators. Instruct the operator to refer to the chart for
instruction avoiding the crack in welding electrode, concentricity of the
die and correct die location.
Prepared by Sponsor, Mr.T.R.K.Prabhu.
Mr.M.Sathiyaraj, Mr.S.Gopal, Mr.K.Sasi,
TSSFD Members
Mr.R.Raman and Mr.V.Ramalingam
Inspection charts for checking the crack in
Supporting documents welding electrodes, concentricity of the die and
correct location of the die.
Endorsement by
 125

Table 5.20 Work Instruction- Baking

TSSFD3-WI 3 of 4
Process/ Function Baking
TSSFD document number TSSFD3 Cause Numbers: C8 C11
Target users Wet powder mixing, Extrusion and Inspection
Highlight the importance of time of natural drying and
Work baking and instruct the operators to refer to the charts
instruction attached in the machine for maintaining exact temperature
and time of drying and baking.
Prepared by Sponsor, Mr.T.R.K.Prabhu.
Mr.M.Sathiyaraj, Mr.S.Gopal, Mr.K.Sasi,
TSSFD Members
Mr.R.Raman and Mr.V.Ramalingam
Supporting documents Temperature range charts fixed in the machine.
Endorsement by

Table 5.21 Work Instruction- Inspection

TSSFD3-WI 4 of 4
Process/ Function Inspection
TSSFD document number TSSFD3 Cause Numbers: C12 14
Target users Wet powder mixing, Baking and Extrusion
Work Inspector may be instructed to inspect the three
instruction characteristics namely smoke, spatter and cracks.
Prepared by Sponsor, Mr.T.R.K.Prabhu.
TSSFD Members Mr.M.Sathiyaraj, Mr.S.Gopal, Mr.K.Sasi,
Mr.R.Raman and Mr.V.Ramalingam
Supporting documents Chart specifying the experience of the inspector
for allowing him/her to check smoke, spatter
and cracks in the welding electrodes.
Endorsement by
 126

5.4.11 Control phase

The TSSFD programme developed should not slip from the exact
path of implementation. For this purpose each TSSFD member is required to
refer to the milestones of implementation. In order to enable this process to
occur at R.K, the TSSFD members are required to enter their observations in
the control card during the completion of every fifth day of TSSFD3 project
implementation in R.K.

5.5 RESULTS AND DISCUSSION

A study of the application of TSSFD project reported in the

previous section would reveal its practical applicability and usefulness. As
mentioned earlier, before beginning the TSSFD3 project, R.K. was found to
operate at the sigma level of 2.874. This is a concerning situation as a
traditional company implementing quality control techniques would
comfortably perform at sigma level greater than 3. This is due to the reason
that, traditional statistical quality control techniques are designed to enable
the companies to achieve three sigma levels. Another aspect is the increasing
use of continual and continuous improvement strategies by the modern
organizations. Because of the adoption of these strategies, modern
organizations are found to operate even at about 4 sigma level. Amidst this
situation, R.K. operating at the sigma level of 2.874 indicated that no concrete
efforts had been made to control and improve quality of the welding
electrodes produced and the processes employed. However this aspect did not
act as a hurdle towards successfully implementing TSSFD3 project.

TSSFD3 could be successfully implemented at R.K. with the help

of the personnel who had gained expertise through practical experiences.
With the exception of the author of this thesis, all the TSSFD3 team members
have not had formal education on welding technology. Despite this
deficiency, all the TSSFD3 team members could share their expertise. Thus
 127

TSSFD was found to be a powerful technique in deriving expert knowledge

gained through practice. This is a valuable observation because practical
human knowledge is valued high in todays globally competitive scenario.

Another interesting observation is that, the expenditure to be

incurred for taking the actions was very negligible. In many cases, it was
found to be nil. As mentioned in the previous section, the results of improve
phase confirmed that the sigma level would become almost equivalent to 6 on
taking the actions. The subsequent stages helped in creating the system
elements to perpetuate the actions. On the whole, the unearthing of practical
knowledge and systematizing the implementation of actions were the major
outcome of TSSFD3 project executed at R.K. This finally has enabled the
R.K. to perform at 5.58 sigma level.

5.6 CONCLUSION

The successful implementation of TSSFD3 project at R.K. has to be

noted with interest due to two reasons. The first reason is that, there is very
little documentation available to imbibe the theoretical knowledge on
manufacturing of welding electrodes. Due to this reason, highly researched
theoretical knowledge could not be imbibed during the implementation of
TSSFD3 project at R.K. The second reason is that, though TSSFD members
possessed no formal education on welding technology, it was possible for the
author of this thesis to coordinate TSSFD3 project at R.K. During this
endeavor, the author of this thesis was able to derive practical knowledge.

The application of TSSFD3 at R.K. was successful and found to be

effective in improving the sigma level from 2.874 to 5.58 (a value nearer to 6)
through the translation of a customer voice denoted as TSSFD3. Finally it
helped the author of this thesis to achieve the objectives specified in the
project charter developed during the define phase of TSSFD3.