Reducing variability in micro-milling process using six sigma methodology

Micro-milling is a manufacturing process used as an alternative for the fabrication of Lab-on-a-Chip components among other medical applications. In the work presented here, the six sigma methodology was used for evaluating micro-milling process parameters and their impact on the generation of geometrical errors such as tool wear, vibrations and burr formations. These critical variables affect surface quality and geometrical features for Lab-On-a-Chip microfluidic performance. This paper presents the application of DMAIC (Define, Measure, Analyze, Improve and Control) methodology in micro-milling process in order to study cutting parameters and their influence on surface quality. Finally, improvements are implemented to enhance process capability as related to surface roughness.