Power Generation gas turbines used for heavy duty application mainly constitutes three modules; compressor, combustion and turbine. Typically, all these parts are designed by OEM companies for specific number of hours and cycles (also known as starts) before they become dysfunctional. In addition, Gas Turbine (GT) also have intended repair interval depending upon the type of part application and anticipated damages during service operation. Thus, GT parts need inspections and repair (overhaul) after certain operating hours in order to recondition them so that they can be fit for reoperation to produce power. In this dissertation, a unique six sigma DFSS approach for development of GT parts overhaul is presented for total quality improvement. In this dissertation report, a unique six sigma DFSS approach is presented applicable to the development of repair processes for GT parts that can be used during overhauling of the parts. All six sigma phases of the proposed DFSS approach along with repair product development cycle are discussed. Various six sigma tools which yield significant benefits for the process users are also discussed. Importantly, a statistical probabilistic life analysis approach is proposed in order to verify the structural integrity of a repaired GT part. Finally a case study of GT axial compressor diaphragms (stators) to illustrate various phases and six sigma tools usage during each phase of the DFSS approach is discussed. The overall significant benefit of the proposed DFSS approach was to achieve total quality improvement to deliver final GT repair process, faster repair development cycle and end customer satisfaction.
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Doctor of Philosophy (Ph.D.)
College of Engineering and Computer Science
Industrial Engineering and Management Systems
Length of Campus-only Access
Doctoral Dissertation (Open Access)
Ghunakikar, Somesh, "A New Six Sigma Implementation Approach For Power Generation Gas Turbines Repair Process Development" (2016). Electronic Theses and Dissertations. 4968.