Resolution of insulation related manufacturing problems using the Six Sigma methodology and tools

Resolution of manufacturing problems can be particularly challenging when making high-voltage stator coils or bars. Manufacturing a virtually void-free integral laminate is difficult due to the variation of resin reactivity, flow, compression and a large number of factors. Recent experience of applying the Six Sigma approach and its data analysis tools to the resolution of manufacturing issues has yielded significant results. This paper describes the overall quality assurance initiative being undertaken by one manufacturer, the Six Sigma approach and demonstrates the benefits of using this disciplined problem solving methodology. Six Sigma is the upcoming quality improvement process and is proving to be a powerful tool for solving complex problems.