Enhancement of Efficiency and Reduction of Grid Thickness Variation on Casting Process with Lean Six Sigma Method

Witantyo, David Setyawan

Research output: Contribution to journalConference articlepeer-review


In a lead acid battery industry, grid casting is a process that has high defect and thickness variation level. DMAIC (Define-Measure-Analyse-Improve-Control) method and its tools will be used to improve the casting process. In the Define stage, it is used project charter and SIPOC (Supplier Input Process Output Customer) method to map the existent problem. In the Measure stage, it is conducted a data retrieval related to the types of defect and the amount of it, also the grid thickness variation that happened. And then the retrieved data is processed and analyzed by using 5 Why's and FMEA method. In the Analyze stage, it is conducted a grid observation that experience fragile and crack type of defect by using microscope showing the amount of oxide Pb inclusion in the grid. Analysis that is used in grid casting process shows the difference of temperature that is too high between the metal fluid and mold temperature, also the corking process that doesn't have standard. The Improve stage is conducted a fixing process which generates the reduction of grid variation thickness level and defect/unit level from 9,184% to 0,492%. In Control stage, it is conducted a new working standard determination and already fixed control process.

Original languageEnglish
Article number012051
JournalJournal of Physics: Conference Series
Issue number1
Publication statusPublished - 22 Mar 2018
Event3rd International Conference on Mathematics: Pure, Applied and Computation, ICoMPAC 2017 - Surabaya, Indonesia
Duration: 1 Nov 20171 Nov 2017


  • battery
  • grid casting
  • lean six-sigma


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