Casting industries play a major role in the field of manufacturing. The production of complex shape and size products is manufactured in a single process, which cannot be produced in other manufacturing processes. Because the other process needs more than one step to convert a raw material into a product. When producing the casting, the quality of the casting should be maintained without defects. This is not possible as we can’t produce a cent percentage of accuracy. But the percentage of defects can be reduced with the help of certain quality control tools and techniques. In this paper, the main focus is to reduce the shrinkage defect which occurs in the External Bearing Ring of ductile cast iron which is produced in the leading casting industry in Coimbatore. The data have been collected from the industry for the six months and the defects have been identified with the help of the Six-Sigma DMAIC (Define, Measure, Analyze, Improve, Control) technique. The quality control tools are applied in different stages of the DMAIC technique for identifying and controlling the defects. Also, the Taguchi technique is applied for creating the L9 orthogonal array from the Minitab software. Finally, the best possible solution is obtained and it is suggested to the industry for defects reduction.

One of the main challenges in Engineering industries is to have materials with extra ordinary properties. Due to the difficulty of availability from open market and economical impact on pure hard materials such as titanium, vanadium, tungsten, titanium & its alloys, an alternative approach is performed through this project. The parent pure metal is bought to the difficulty to machine level of hardness and various parameters were analyzed on hard turning operation. Pure EN-31 round bar is considered for this purpose and this is bought to a hardness level of 60-64 HRC, so as to understand the variation in certain parameters, since limited studies were conducted towards the behavior of cutting tool during CBN hard turning. CBN tool were used for the this purpose. Thus this is an investigation on the influence of cutting parameters in hard turning .The combined effect of the process (cutting speed, feed rate and depth of cut) on performance characteristics (surface roughness and chip morphology) are investigated through the analysis of variance (ANOVA). The design of experiment has conducted through Taguchi approach and conformation of experiments is performed through Regression analysis by using MINITAB-17 software. The output variables considered are the surface roughness and the type of chips generated (chip morphology). Chip morphology analysis considers only for continues and discontinues chip as the cutting tool used is CBN. From the experiment it is found that the dependent parameter in surface roughness measurement for Ra, Rq and Rz is feed rate.

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