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Process improvement of hardening furnace (mapping) in tool industry – A case study

The aim of this paper is to identify the temperature variation within a furnace and also find the variation of hardness in a tool after quenching. The paper takes a case study approach, demonstrating how theory has been used in practise and using one way ANOVA to estimate the optimum number of tool grinding required before inspection. The case study was carried out at a leading hand tool manufacturer in India. Lean Six Sigma (LSS) is found to work very well in the tool manufacturing industry for improvement the process. The LSS strategy for manufacturing industries shows how merging statistical and analytical tools helps to improve process efficiency. Our primary constraint was the measurement instrument, which was a thermal laser gun that could only correctly measure one metre values. This study shows an application of one-way ANOVA and lean/six-sigma concepts to process improvement. The major goal of this study is to show how combining Lean concepts/techniques with one-way ANOVA and Six-Sigma methodology can help solve problems faster.