Following the initial molten metal quality studies with the MetalVision Inclusion Analyzer 1,2 , the need for more robust molten metal treatment equipment and methods was identified. Through Rapid Improvement Events and other Six Sigma techniques, systematic changes were introduced and closely monitored. Significant improvements were made in melting, degassing and filtration that resulted in the ability to adapt the production process to varying raw material types. The changes made are

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... as well as their effects on the molten metal quality measurements.. Implementation challenges and the follow up control ensuring uniform and consistent sustainable benefits are also discussed. Data is presented proving that final product quality has improved as measured by in plant non-conformances and the goal of zero customer returns and complaints.