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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.

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