In the modern era of business practice, furnace plays an imperative role in metal extraction, metal forming
and heat treatment process. The furnace products manufacturers maintain global competitiveness through strategic
energy management by using energy efficient technologies. The performance of the furnace strives to enhance the
quality by considering efficiency and performance of the furnace together. Among the various methods available to
improve the furnace performance, a systematic approach should be used for achieving impetus improvement at an
affordable cost. In engineering arena, the complexity reduction of the functional unit can be achieved through either
break down of the system or process. The furnace has some basic performance influential components namely heat
exchanger, nozzle, burner and control valve. The performance of individual components can be evaluated and
integrated to embark the total performance of the furnace. The strict investigation was taken over to identify and
eliminate the vital parameters that affect the efficiency of the furnace through a systematic approach namely Six
Sigma DMAIC (Define, Measure, Analyze, Improve, and Control)phases. Six Sigma is a quality management tool
introduced by Bill Smith of Motorola in 1980 [1]. It is said to be fierce approach that directly hits imperative woes
faced in customer end, by reducing the variation to achieve 3.4 defects per million opportunities (DPMO) that
subsequently enhance the quality, market share of the manufacturing organization. The variations are controlled by
using a hierarchical approach of Six Sigma DMAIC, which have been derived from Deming’s improvement cycle
namely PDCA (Plan-Do-Check-Act). This case study narrowly performs investigations on improving current
performance of heat exchanger that improves the overall efficiency of the furnace by using the Six Sigma DMAIC
approach. In this regard, the atmospheric air is preheated for complexity reduction through exhaust flue gas of a
furnace. The preheating of combustion air illuminates to reduce energy loss in the furnace by improving overall
efficiency. This preheating process provides 10–30 percentage monetary savings with the economical fuel usage
In the modern era of business practice, furnace plays an imperative role in metal extraction, metal formingand heat treatment process. The furnace products manufacturers maintain global competitiveness through strategicenergy management by using energy efficient technologies. The performance of the furnace strives to enhance thequality by considering efficiency and performance of the furnace together. Among the various methods available toimprove the furnace performance, a systematic approach should be used for achieving impetus improvement at anaffordable cost. In engineering arena, the complexity reduction of the functional unit can be achieved through eitherbreak down of the system or process. The furnace has some basic performance influential components namely heatexchanger, nozzle, burner and control valve. The performance of individual components can be evaluated andintegrated to embark the total performance of the furnace. The strict investigation was taken over to identify andeliminate the vital parameters that affect the efficiency of the furnace through a systematic approach namely SixSigma DMAIC (Define, Measure, Analyze, Improve, and Control)phases. Six Sigma is a quality management toolintroduced by Bill Smith of Motorola in 1980 [1]. It is said to be fierce approach that directly hits imperative woesfaced in customer end, by reducing the variation to achieve 3.4 defects per million opportunities (DPMO) thatsubsequently enhance the quality, market share of the manufacturing organization. The variations are controlled byusing a hierarchical approach of Six Sigma DMAIC, which have been derived from Deming’s improvement cyclenamely PDCA (Plan-Do-Check-Act). This case study narrowly performs investigations on improving currentperformance of heat exchanger that improves the overall efficiency of the furnace by using the Six Sigma DMAICapproach. In this regard, the atmospheric air is preheated for complexity reduction through exhaust flue gas of afurnace. The preheating of combustion air illuminates to reduce energy loss in the furnace by improving overallefficiency. This preheating process provides 10–30 percentage monetary savings with the economical fuel usage
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