Abstract:
In India there are many foundry have followed conventional and manual operations. Today’s competitive environment has, more productivity in less time, lower manufacturing cost and improve quality product, defect free operation are required to follow to every foundry staff. Mold shifting, Crushing, Lower Surface finish, Shrinkage, Porosity, Cold shut and Extra material are common casting defects due to these manual processes. These defects are directly affected on product, profit and quality level of organization. The paper presents analysis of these defects with Pareto and Cause and Effect diagrams to know correct cause and correct remedial factors to improve quality level and productivity of organization. In the present global and competitive environment foundry industries needs to perform efficiently with minimum number of rejections. Also they have to develop casting mechanism in very short lead time. Casting process is still state of art with experienced people but these experience needs to be transformed in engineering knowledge for the better growth of the foundry industries and quality. Some foundries are working with trial method and get their work done. Actually, most of the foundries have very less control on rejections. Majority foundries are failed to maintain a satisfactory quality control level. Defect free castings with minimum production cost have become the need of the foundries. The move toward taken by this paper is expected to motivate the foundries to use a standard classification system to describe undesirable casting artifacts for more useful failure analysis. It will also give confidence foundries to develop systems to measure process parameter relating to the defects that happened in the foundries and pool the resources of area experts. Any reduce in the waste and rework also positively influences the environmental impact of our industry. In this paper its deals the various aspects of an organized approach to understanding and development of quality cost system in cast iron foundries. This study is improved the quality and productivity of entire process of casting manufacturing.
