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Six Sigma Methodology Analysis Applied to Extrusion Plant

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Six Sigma Methodology Analysis Applied to Extrusion Plant

Rodrigo Camargo Campana, Companhia Brasileira de Alumínio, São Paulo, Brazil

Track: MANAGEMENT ISSUES - Operations

ABSTRACT—The Six Sigma methodology was created by the mid-1980s, focusing mainly in
the reduction of manufactured defects. This methodology is based on the DMAIC model (Define,
Measure, Analysis, Improvement, and Control). The Votorantim Metais - Companhia Brasileira
de Alumínio started the implementation of this methodology in the middle of 2006, with projects
for the foundry plant reaching to the extrusion plant in the beginning of 2008. During this period,
29 projects were developed in different areas of the extrusion plant, such as planning, die shop,
anodizing, maintenance, presses, quality, and process. The present work used Six Sigma
methodology to identify the main causes, trends, and relations that influence the knock-off index
by runout difference between holes in the 1250-ton press, and the scrap process in the 3300-ton
press at VM-CBA. All projects raised the capability of the processes at least by 20 percent,
reducing their variation and adding $10 million (U.S.) as a gain of EBITDA (Earnings Before
Interest, Taxes, Depreciation and Amortization) for the extrusion. Key-words: Six Sigma,
DMAIC, extrusion, gain.

© Extrusion Technology for Aluminum Profiles Foundation (ET Foundation). All rights reserved. No part of The Proceedings may be reproduced in any form without the express written permission of the ET Foundation.