Spiral welded pipe improvement by implementation of Six Sigma

Purpose: Online spiral pipe manufacturing is one of the most common processes for producing water and gas transmission pipes. Weld quality and pipe circumstances are the most important qualitative characteristics of these pipes determining the overall cost of production. The purpose of this paper is describing how to implement Six Sigma on the production of spiral welded pipes with a real case study. Design/methodology/approach: First, the capability of the pipe production process has been performed by using the defects per million opportunities to allow for comparison and analysis of the project effectiveness. Then, the variation pattern of this index, after an improvement project, has been investigated. Finally, Taguchi's loss functions are used to evaluate the effectiveness of these projects. Findings: The results represent a significant improvement in the production process and a reduction in production costs regarding both weld quality and pipe circumstances. Due to the successful implementation of Six Sigma project in welding and pipe quality improvement, the Define, Measure, Analyze, Improve and Control (DMAIC) method can be used effectively in defining weld and pipe quality. Originality/value: In this proposed work, for the first time, research on the implementation of Six Sigma in the pipeline and welding industries on two online spiral production machines has been investigated. The DMAIC method has been used for the first time to improve the dimensional quality and weld quality of spiral pipes.