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In porcelain manufacturing, the quality control is main characteristic because of the delicate nature of the aesthetics and the product’s composition. This research looks into one of the most problematic defects identified at the handle attachment of Regular body mugs, which shows a serious problem to quality and contributes to high rejection rates in the final inspection. With the 6σ methodology, according to the DMAIC, the study systematically attempts to solve the problem's underlying root causes. Over a three-month period, relevant data were collected through final inspection reports and field studies for problem identification and root cause analysis. This was analyzed using Pareto charts, cause-and-effect diagrams and 5-Why analysis. Main controllable root causes included handle-making methods, attachment bonding areas, and decoration kiln pre-heating time adjustments. To validate these root causes, 3 suggestions were tested: switching the handle casting from solid to drain casting, maximizing the attachment bonding area, and maximizing RHK preheating times. These improvements were checked through quality inspections at every stage using NDT. The 4M validation and control impact chart helped distinguish between controllable and uncontrollable causes. The final inspection results confirmed a significant amount of defect reduction in handle attachment crack defects and other main defects.

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Root Cause Analysis and Mitigation of Defects on Handle Attachment in Porcelain Products Using 6σ-DMAIC Methodology

  • 会议论文

  • 发表日期：

    2026年

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  • Vihanga Chandrasekara,
  • Roshan Thilakarathne

摘要

In porcelain manufacturing, the quality control is main characteristic because of the delicate nature of the aesthetics and the product’s composition. This research looks into one of the most problematic defects identified at the handle attachment of Regular body mugs, which shows a serious problem to quality and contributes to high rejection rates in the final inspection. With the 6σ methodology, according to the DMAIC, the study systematically attempts to solve the problem's underlying root causes. Over a three-month period, relevant data were collected through final inspection reports and field studies for problem identification and root cause analysis. This was analyzed using Pareto charts, cause-and-effect diagrams and 5-Why analysis. Main controllable root causes included handle-making methods, attachment bonding areas, and decoration kiln pre-heating time adjustments. To validate these root causes, 3 suggestions were tested: switching the handle casting from solid to drain casting, maximizing the attachment bonding area, and maximizing RHK preheating times. These improvements were checked through quality inspections at every stage using NDT. The 4M validation and control impact chart helped distinguish between controllable and uncontrollable causes. The final inspection results confirmed a significant amount of defect reduction in handle attachment crack defects and other main defects.