Confluence of Six Sigma, simulation and environmental quality: An application in foundry industries

The aim of the research is to use an integrated approach – simulation and Six Sigma to improve the ambient air quality.

Integration of simulation and Six Sigma DMAIC methodology in a foundry had been used to improve the ambient air quality. Various elements of the Six Sigma toolkit such as Cause and Effect diagrams and Failure Mode and Effect Analysis have been used to discover the root causes underlying the problem and prioritize action and incorporate cost‐effective solutions. Simulation has been used to improve and control the environmental efficiency by monitoring the performance of the Venturi Scrubber – the pollution control equipment, by running the model under varying conditions.

The integrated application of Six Sigma and simulation has been successful in reducing particulate emissions from 200 milligrams per cubic meter to less than 20 milligrams per cubic meter and sulphur dioxide emissions from 45 milligrams per cubic meter to less than 4.5 milligrams per cubic meter, thus reducing air pollution.

Air pollution is a burning problem in the present scenario and foundry industries are one of the contributors to air quality degradation. The approach described in this paper is a step towards reducing air pollution due to foundry operations.

Integration of Six Sigma DMAIC methodology and simulation provides a novel cost‐effective strategy for monitoring and reducing air pollution resulting from foundry operations. This paper is useful for environmental division of foundry and other manufacturing industries.