Foundry quality control aspects and prospects to reduce scrap rework and rejection in metal casting manufacturing industries

Vijayaram, Thoguluva Raghavan; Sulaiman, Shamsuddin; Ahmad, Moyeen

doi:10.1016/j.jmatprotec.2005.09.027

Cited by 40 publications

(17 citation statements)

References 8 publications

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“…However, in our literature survey (Reid, 2006;Huang et al, 2002;Vijayaram et al, 2006), we have found any instance of OEE improvement through the use of techniques like abnormality identification sheet and why-why analysis. It inspires to implement the total productive maintenance (TPM) procedures in textile sick industry.…”

Section: Background For the Researchmentioning

confidence: 84%

A simulation-based analysis for improvement of productivity in sick chemical dyeing factory: a research article

Sivakumar¹,

Saravanan²

2011

IJET

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This paper provides an overview of the various processes in textile fabric industry. From the analysis of data taken during the past three years, the company has noted that it has not achieved the targeted productivity. Total productive maintenance (TPM) has been a major component of improvement strategy to enhance the organisational productivity and profitability. Identification of resources and use resources play a critical role in any industry for the improvement of quality and productivity. For example, fabric industry could not get the determined productivity since TPM was not followed. The objective of this paper is to present the result of the past three years productivity data and discussed different results obtained after implementing the procedures of TPM in the failure textile industry. A systematic methodology is presented and analysed by software for improvement productivity at the factory level. Metrics of overall equipment effectiveness (OEE) is introduced and developed a structured robust framework for improvement of quality and productivity.

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Section: Background For the Researchmentioning

confidence: 84%

A simulation-based analysis for improvement of productivity in sick chemical dyeing factory: a research article

Sivakumar¹,

Saravanan²

2011

IJET

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“…The process evaluation is made post factum -only after it is finished and an appropriately large sample is collected. Despite that these charts require a definitely larger sample than the variable charts and are less informative, they allow current evaluation if defectiveness level of a supervised process does not exceed an acceptable one (this level is determined on the basis of a specifically prepared pilotage trial) [18].…”

Section: Idea Of Demerit Control Chartmentioning

confidence: 99%

Demerit control chart as a decision support tool in quality control of ductile cast-iron casting process

Sika

Rogalewicz

2017

MATEC Web Conf.

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Abstract. In many industrial areas the product quality can be unequivocally assigned to classes such as: "good", "bad" or "to repair". In case of casting processes, the product is approved to sales considering customer's requirements. Except for common characteristics, such as structure, compactness and mechanical properties, physical state of the product is also important. This state is assessed by checking occurrence of specific kind of defects. They are often conditionally accepted by a customer if they do not have any influence on functionality of the product (e.g. negative adhesive and cohesive phenomena, fatigue strength, thermal shocks). Authors' experience shows that current registering of the most frequently occurring defects and comparing them to customers' requirements can be very useful and help a quality engineer to control the casting process. They suggest using the Demerit Control Chart (DCC), according to authors' own methodology, in aspect of information about the castings accepted conditionally by a customer (DCC-recognition). DCC-recognition can be used to assess this quality by monitoring the value of just one aggregated measure for all kinds of defects instead of using a single attribute control chart for each of them. The test version of this tool considering severity of defects proved to be useful in one of the European foundries.

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“…The production concerns must follow the quality control procedures correctly and perfectly to produce quality casting. With the passage of time the modified techniques based on the quality control research is became must to avoid defects in the products [2]. Sand is used by means of different processes: green molding, shell, No-bake, hot box, cold box and others.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Critical Parameters for Sand Inclusion Defect in FNB Casting

Acharya¹,

Vadher

Kothari

2017

Archives of Foundry Engineering

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Casting covers major area of production all over the world. Resin bonded casting is widely used in today's manufacturing industries. Furan No bake casting is most widely accepted in indian foundries due to its excellent surface finish and dimensional stability. It is a self-setting binder and it has a lower work and strip times. Though the casting process is also known as process of uncertainty, in the present study, an attempt has been made to investigate the effect of Grain Fineness Number, Loss of Ignition, Potential of Hydrogen, % of Resin with respect to sand, Sand Temperature and Compressive strength of the mould on Sand Inclusion defect -one of the most dominating defect in the Krislur Castomech Pvt. Ltd. Industry situated at Bhavnagar, Gujarat, India. The experiments were conducted based on response surface methodology (RSM) and sequential approach using face centered central composite design. The results show that quadratic model with removal of some insignificant term is comparatively best fits for Sand Inclusion Defect.

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Foundry quality control aspects and prospects to reduce scrap rework and rejection in metal casting manufacturing industries

Cited by 40 publications

References 8 publications

A simulation-based analysis for improvement of productivity in sick chemical dyeing factory: a research article

A simulation-based analysis for improvement of productivity in sick chemical dyeing factory: a research article

Demerit control chart as a decision support tool in quality control of ductile cast-iron casting process

Evaluation of Critical Parameters for Sand Inclusion Defect in FNB Casting

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