IMPLIMENTATION OF TOTAL QUALITY MANAGEMENT IN FOUNDRY SHOP
Patel Chirag1, Patel Khushil
2, Wagh Shankar
3, Sirvi Narayanlal
4
Student, Mechanical department, Laxmi institute of Technology, Sarigam-Valsad. Gujarat
Corresponding Author Detail:
Patel Chirag
Student, Mechanical department,
Laxmi institute of Technology,
Sarigam-Valsad, Gujarat.
Internal Guide Detail:
Mr. Ashish Patel
Assistant Professor, Mechanical department,
Laxmi institute of Technology,
Sarigam-Valsad. Gujarat.
ABSTRACT
Purpose: The main purpose of this case study ,we study and understanding the importance
about Total Quality Management implementation in foundry shop. Today’s competitive
environment has lower manufacturing cost, more productivity in less time, high quality
product, defect free operation are require to every industry so we are going to implement
Total Quality Management through Quality Assurance Plan in foundry shop that will help the
industry reduce the various defects.
Design/Methodology/Approach: In this review paper we have collect the data though the
process mapping & then find major defect and their causes and choose the best solution to
improve it by optimize that data using taguchi method using software of Minitab.
Finding: Researcher finding causes and remedies for various casting defects (Blow hole,
Shrinkage, Sand inclusion) and select the parameter (poring temperature, permeability, mould
hardness, moisture) that affect the casting product quality.
Originality/Value: This study used to shows beneficial work an attempt to get technical
solution for minimizing various casting defect and to improve entire process of casting
manufacturing using Total Quality Management.
KEY WORDS: TQM, Taguchi method, Quality Assurance, Casting Defects
INTRODUCTION
Total Quality Management is a management approach that originated in the 1950's and has
steadily become more popular since the early 1980's. Total Quality is a description of the
culture, attitude and organization of a company that strives to provide customers with
products and services that satisfy their needs. The culture requires quality in all aspects of
the company's operations, with processes being done right the first time and defects and
waste eradicated from operations.
Total Quality Management = Total + Quality + Management
Total: Integration of all functions, all activities, all employees, all sub-customers etc.
Quality: Measure of customer satisfaction and delight with the product and service or
conformance to specification and such other physical features.
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Management: Leadership, Organization structure working system procedure and process to
make it people happy.
Nandratan foundry shop is facing casting rejection due to some defect , after observing data
of the company most frequently rejected casting identified were Axle End Cover , Rear
Cover , Deluge Valve. Out of these Axle End Cover was identified as most severely affected
casting, hence it was considered for detailed investigation.
The work on Quality Improvement of casting was carried in following step:
• Identification of defect in Axle End Cover casting and analysis
• Selection of most defects which frequently occurred and carried out the analysis.
• Identification of root causes and finding the remedial measures.
• Production trials in the company with the remedial measures and validation.
Figure-1 Photography of AXEL END COVER
METHODOLOGY
Figure-2 Methodology
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LITERATURE REVIEW:
Sr.
No
Name of
Research
Paper
Name of
Author
Name of
Journal
Tools and
Techniques
Used
Learning of Paper
1. Reducing
casting
defects
and
improve
productivi
ty in
small
scale
foundry
Chirag
B. Patel
Hemant
R.
Thakkar
International
Journal of
Advanced
research in
Engineering,
Science and
Management
Seven Quality
control tools,
productivity,
casting
defects, cold
shut
It is suggested that careful
supervision with effective
motivation of individual
employees in achieving the
quality is a must in
reducing the rejection and
scrap in metal casting
manufacturing engineering
industries
2. Quality
Improve
ment for
Dimensio
nal
Variation
s in sand
Casting
Using
Quality
Control
Tools
Abhijeet
B. Vante
G.R.Naik
International
Journal of
Innovative
Research in
Science,
Engineering
and
Technology
Quality
Improvement,
Pareto
Analysis,
Ishikawa
Diagram,
Quality
Control Tools,
Brainstorming,
casting.
Initial research shows that
casting is facing higher
percentage of rejection due
to dimensional variations at
casting wall.
3. Review
on Expert
Systems
for
Casting
Defects
Analysis,
Diagnosis
and
Preventio
ns
P.
Sathish
Kumar,
Dr. A.
Ramesh,
K.Sathish
kumar
International
Conference
on
Breakthroug
h in
Engineering,
Science &
Technology
ESVOD, Web
CADAS,
Web-based
systems,
analysis,
diagnosis
This will help the various
departments including
Quality control for
diagnosis and prevention in
castings to minimize the
production time, casting
defects , cost and forms a
key tool for mass
production.
4. A
developm
ent of
quality in
casting by
Prasan
Kinagi,
Dr. R.G
MENCH
International
Journal of
Recent
Research in
Civil and
Casting,
FMEA, DOE,
Taguchi
methodology,
Pareto analysis
All factors considered
contribute to the quality of
performance
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minimizin
g
Mechanical
Engineering
(IJRRCME)
5. Minimiza
tion of the
casting
defects
using
taguchi’s
method
Harvir
Singh,
Aman
Kumar
International
Journal of
Engineering
Science
Invention
foundry Shop,
Casting
Defects,
Taguchi’s
Method, Sand
Casting,
Check Valve
PN 10
we have studied minimize
the casting defects using
Taguchi’s method through
change in various
parameters like as pouring
temperature, green strength,
mould hardness and
permeability.
6. Review
analysis
of casting
defects
with
respect to
indian
standards
in cast
iron
foundry.
Narayana
swamy.C
,
Natarajan
.K
Journal of
Chemical
and
Pharmaceutic
al Sciences
Foundry,
Castings,
defects,
rejections,
Causes,
Remedies,
Quality.
castings are inspected with
technologically advanced
way, it keeps foundry men
to alert condition for
control of rejections and it
will be within limit
specified by the Indian
standard.
7. Present
approache
s for
analysis
of casting
defects.
P.
Sathish
Kumar,
A.
Ramesh,a
nd M
Gokul
ARPN
Journal of
Engineering
and Applied
Sciences
Pareto
analysis,
cause-effect
diagrams,
design of
experiments,
artificial
neural
network
Rejections of casting on the
basis of the casting defect
should be as minimized
Table-1 Literature Review
DATA COLLECTION
IDENTIFICATION OF CASTING DEFECT NANALYSIS
The frequently rejected castings identified at Nandratan Foundry are Axle End Cover, Rear
Cover, Debuge Valve etc. AEC casting comprises 15-20 percent of total production of the
company. The number of castings produced in the month of June 2010 and their weight,
quantity and cost per kg are given below.
As the production of AEC is maximum and its cost of rejection is highest this casting was
considered for detail study. AEC casting is having defects such as sand drop, blow hole,
shrinkage, mismatch, sand fusion, cold shut etc. The data observation of defects in AEC
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casting shown in Pareto Chart . It may be noticed that the most occurring casting defects are
Sand drop, Blow holes, Mismatch hence they were picked up for detailed study. To
understand the reason for causes of these four defects a detail study was carried out in
foundry.
The rejection data for a month period were collected and drawn as parato graph is shown in
the figure.
IDENTIFY MAJOR DEFECT
Foundry Defect Analysis using Parato - Lorenzo Analysis
Figure shows the parato analysis for the various type of casting defect. In fig. various defect
are arranged according to their respective rejection percentage. From the prarto analysis it
is clear that major defect is blow hole is maximum occur defect and other defect are
shrinkage and sand inclusion.
Figure-3 Major casting defect as parato graph
CAUSE AND EFFECT DIAGRAM FOR BLOW HOLE AND SHRINKAGE
Another tool of quality management used in this work is the cause and effect diagram that
will help us to separate the effect from causes of problem and to minimize the complexity of
the problem.
Figure-4 cause and effect diagram for blow hole and shrinkage
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Figure-5 cause and effect diagram for blow hole and shrinkage
CASTING DEFECT ANALYSIS AND REMEDIES MEASURE
DEFECT CAUSES REMEDIES
1.Blow Holes
Gases entrapped by solidifying metal on
the surface of casting, which result
round shape cavity on the surface after
shot blasting
Insufficient
permeability of molding
or core sand.
Avoid fines particle in
the sand.
High moisture content
of mould.
Minimize sand water
content in the sand mix.
To low pouring
temperature.
Increase pouring
temperature as possible.
Hard ramming. Avoid excess ramming.
2.Shrinkage
When feed metal is not available to
compensate the shrinkage as the metal
solidifies.
Incorrect feeding. Design correct gating
and feeding system.
Weak mould. Improve mould
hardness
High pouring
temperature.
Adjust gating system
properly.
3.Sand Inclusion
Irregularly formed sand inclusion close
to casting surface combined with
metallic protuberance at other point
Faulty gating system. Modify gating system.
Faulty pouring. Improve pouring to
minimize turbulence.
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Table-2 Casting Defect Analysis And Remedies Measure
DATA COLLECTION AND SELECTION OF BEST SOLUTION
Rejection Datasheet: Data collection (Before implementation) – AXLE END COVER
Following table shows the total production and data of t6hree month. Total rejection of Axle
End Cover is given in following table. We see the approx 85 % of total rejection of
component is due to these defect like blowhole, shrinkage, sand inclusion, etc.
Table-3 Rejection Datasheet
Total production of three months = 1390 Total rejection = 75 piece
% of rejection = 75/1390 = 0.0539 x 100 = 5.39%
Control factor of process parameters and their levels
Process parameter of casting that affect the identify defect of Axle End Cover with their level
are shown in table.
Parameter Range Level A Level B Level C
Pouring temperature(oC) 1300-1350 1300 1320 1350
Permeability 170-200 170 185 200
Sand particle size(Afs) 60-65 60 62 64
Mould hardness(Nu) 85-95 85 90 95
%Moisture 4-6 4 5 6
Table-4 Control factor of process parameters and their levels Datasheet
EXPERIMENTAL (L9) ORTHOGONAL ARRAY:
Here four parameter with three different levels therefore L9 orthogonal array is selected for
the experimental trial. As per L9 orthogonal array nine experiments were performed by us in
industry.
Rough handling of mold
and core.
Use of superior sand of
good strength, provide
hard ramming
Month Total tested
pieces
Total
Rejection
Blow
hole
Shrin
kage
Sand
inclusion
Other %
Rejection
October 2016 513 27 12 7 5 3 5.26%
November 2016 647 35 18 8 7 2 5.40%
December 2016 230 13 7 4 1 1 5.65%
Total 1390 75 37 19 13 6 5.39%
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Trial
no
A B C D
Pouring
temperature(o
C)
Permeability Mould
hardness(Nu)
%Moisture
1 1300 170 85 4
2 1300 185 90 5
3 1300 200 95 6
4 1320 170 90 6
5 1320 185 95 4
6 1320 200 85 5
7 1350 170 95 5
8 1350 185 85 6
9 1350 200 90 4
Table-5 Experimental (L9) Orthogonal Array Datasheet
The main of study was to reduce the casting defect in foundry shop. The analysis was carried
out by using MINITAB – 17 statistical software in which the S/N ratio is calculate by using
the smaller the better quality characteristics [-10 × log10 Σ (Y2/n)].
There are three categories of quality characteristics in the analysis of S/N ratio, i.e. smaller-
the-better, larger-the-better, nominal the better. As the main aim of the study was to reduce
the casting defect for which the ideal value is zero, the S/n ratio for each level of process
parameter has been computed by using a quality characteristics smaller-the-better.
MEAN VALUE AND S/N RATIO OF CASTING DEFECT:
Trial no % defect in experiment S/N ratio Mean
1 6.18 -15.8919 6.18
2 4.6 -13.6248 4.6
3 6.78 -16.6245 6.78
4 3.87 -11.7542 3.87
5 6.12 -15.7350 6.12
6 6.51 -16.2716 6.51
7 5.06 -14.0830 5.06
8 5.89 -15.4023 5.89
9 3.61 -15.8919 3.61
Table-6 Mean Value and S/N Ratio of Casting Defect Datasheet
S/N = -10 × log10 Σ (Y2/n) = -10 × log10 Σ (6.18
2 / 1) = -15.8919
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MINITAB WORKSHEET:
Pouring
temperature
Permeability Mould
hardness (Nu)
%Moisture Mean S/N ratio
1300 170 85 4 6.18 -15.8919
1300 185 90 5 4.6 -13.6248
1300 200 95 6 6.78 -16.6245
1320 170 90 6 3.87 -11.7542
1320 185 95 4 6.12 -15.7350
1320 200 85 5 6.51 -16.2716
1350 170 95 5 5.06 -14.0830
1350 185 85 6 5.89 -15.4023
1350 200 90 4 3.61 -11.1501
Table-7 Minitab Worksheet
DISCUSSION AND RESULT
From the main effect plot shown below it can conclude that optimum value of pouring
temperature is 1350(oC), permeability 170(NO), mould hardness 90 and moisture 4%.
Figure-6 Result Analysis
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AVERAGE S/N RATIO VALUE FOR EACH FACTOR
LEVEL Pouring
temperature
Permeability Mould
hardness(Nu)
%Moisture
A 15.4 14.4 15.5 14.2
B 14.6 14.5 12.2 14.6
C 13.6 14.7 15.9 14.5
Table-8 Average S/N Ratio Value for Each Factor
OPTIMUM VALUE FOR EACH FACTOR
FACTOR SNR LEVEL OPTIMUM VALUE
Pouring temp. 13.6 C 1350
Permeability 14.4 A 170
Mould hardness(Nu) 12.2 B 90
%Moisture 14.2 A 4
Table-9 Optimum Value for Each Factor
FINAL RESULT AND CONCLUSION FOR CONFORMATION TRIAL OF AXLE
AND COVER
BEFORE EXPERIMENT AFTER EXPERIMENT
Month % Rejection Month % Rejection
October 2016 5.26% January 2017 4.78%
November 2016 5.40% February 2017 4.21%
December 2016 5.65% March 2017 4.48%
Average % of rejection 5.39% Average % of rejection 4.49%
Table-10 Final result
Total % of Improvement = 5.39 – 4.49 = 0.90 %
After implementation of above technique we conclude that optimum value of pouring
temperature is 1350(oC), permeability 170(NO), mould hardness 90 and moisture 4%.
From the data collection of previous data and after implementation solution we reduce the
casting defect of Axle End Cover.
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