Lean Manufacturing- LMCS, Government of India

Welcome

Presentation
Casting Defects- Sand Drop- Proposed Improvement
HPAPL-AACMS Lean Group-1

By
K R Sharma
Lean Six Sigma Consultants Private Limited
Jaipur
 Lean Manufacturing- LMCS, Government of India

Casting Defects Historical Data

Month Total In house Sand Cold Mould Shifting Slag Shrin Misc Ex. PH Swelling Blow
Rejection PPM Drop Metal break k . Cut Hole

April-14 13.01 130100 46.37 16.65 10.62 2.23 17.58 0.45 2.23 1.34 0.78 1.63 0.02
May-14 12.41 124100 50.54 13.60 4.44 10.58 11.91 1.75 2.12 1.04 1.01 2.91 0.16
June-14 12.69 126900 39.70 14.57 5.35 10.50 17.47 1.68 4.36 1.63 2.45 2.13 0.11
July-14 13.88 138800 37.53 12.38 8.84 11.31 10.79 8.49 0.89 4.96 3.67 0.87 0.27
Augu,-14 9.59 95900 46.40 15.88 8.07 8.18 9.43 2.97 2.19 2.58 2.97 1.16 0.17
Sept-14 12.12 121200 41.64 14.12 7.96 11.50 6.29 7.58 4.33 0.03 5.60 0.88 0.06
Octo.-14 10.46 104600 52.64 8.07 7.49 5.16 6.39 5.70 5.79 1.52 6.72 0.91 0.08
Nov.14 16.34 163400 36.42 6.10 9.80 8.25 9.15 5.67 6.09 16.60 1.13 0.53 0.27
Dec-14 10.87 108700 41.51 14.00 14.49 7.36 5.17 3.99 3.05 7.10 1.56 1.11 0.66
Janu- 15 12.59 125900 40.46 7.22 20.81 10.25 9.23 1.90 1.77 3.48 3.05 1.08 0.78
Feb-15 12.57 125700 42.77 10.69 12.80 8.69 4.50 5.70 7.41 2.48 2.34 2.02 0.64
March-15 13.90 139000 37.56 6.66 9.66 10.26 14.46 7.78 4.49 3.36 3.33 2.32 0.13
April-15 15.50 155000 39.01 8.84 13.81 7.46 13.39 4.55 5.51 1.91 0.81 4.49 0.27
May-15 14.81 148100 34.05 9.05 8.76 13.37 7.31 12.76 3.56 3.06 1.00 5.29 1.82
June-15 15.01 150100 30.36 9.81 13.59 24.87 6.69 1.78 4.52 2.99 1.47 3.48 0.45
July-!5 10.42 104200 38.94 9.15 16.59 15.03 2.63 4.11 6.29 1.98 1.57 2.47 1.82
Average. 12.94 129400 40.97 11.04 10.81 10.31 9.52 4.80 4.03 3.50 2.47 2.02 0.43
 Lean Manufacturing- LMCS, Government of India

% Defect Occurence
45
40.97
40

35

30

25

20

15
11.04 10.81 10.31
9.52
10

4.8 4.03
5 3.5
2.47 2.02
0.43
0
 Lean Manufacturing- LMCS, Government of India

Sr Activities Month wise activities

# Aug. Sept Oct. Nov. Dec. Jan Feb. Mar.

1 Analysis of historical data

2 Team formation
3 Understanding of the project
and Team Training
4 Select Defect
5 Role Assignment
6 Measurement of Process Data

7 Identifying Parameters affecting

the defect
8 Brain storming and 7 QC tools

9 Improvements/ Corrective
Action Apply DoE-CTQs
10 Measure the result of DoE—
Corrective actions
11 Preventive Actions
12 Periodical Review of corrective
Actions and Preventive actions
13 Revise SOPs
 Lean Manufacturing- LMCS, Government of India

Team Formation

I P Dua Team Leader, Yogesh Sharma

Jaikishan Akshit Gupta Mansingh Shiva Chauhan

Gajendra Preetam Upendra Vishnu

 Lean Manufacturing- LMCS, Government of India

Roll Assignment

Project guide and design aspect: Shri I P Dua Team Leader

Sand Preparation and Testing- Shri Yogesh Sharma:

Preetam and Vishnu

Charge Preparation and Melting: Shri Gajendra

Moulding : Shri Jaikishan

Mould hardness and Pouring Measurements: Shri Mansingh

Closing of Moulds: Shiva Chauhan, and Upendra

Pouring: The teams are formed from the Moulding machine operators
 Lean Manufacturing- LMCS, Government of India

DoE- Data Collection- Parameters identified

•Metal Temperature
•Pouring Speed/ Pouring Time
•Mould hardness
•Green Sand Composition and properties i.e.
GCS, Moisture content, Permeability and the Compact ability
•Product wise recording of defects
•Sand Temperature
•Metal to sand ratio
•Addition/ removal of sand
•The sand Mixing time
 Lean Manufacturing- LMCS, Government of India

The observed Sand Composition and properties: ( 14.9.2015)

Time Heat Sand Green GCS Permeabil Moistur Compact Metal New
no Mixing Sand (1000 ity e ability to Sand
time Temperatu to (90 to ((4 to (40 to 45) sand added
re 1400) 140) 5%) ratio

2.10 PM 3 3 46 1190 115 4.5 45 1:7.38 10 Kg

(0.5+2.5)
Minutes
4.15 PM 4 3(0.5+2.5) 42 1230 122 4.3 41 1:7.38 10 Kg
Minutes

5.00 PM 5 3(0.5+2.5) 58 1020 105 5.5 52 1:7.38 10 Kg

Minutes
 Lean Manufacturing- LMCS, Government of India

Mould Hardness observed

Sr# Mould Hardness Observed
Heat no 3 Heat no 4 Heat no 5
Cope Drag Cope Drag Cope Drag
1 90-95 90-95 90-95 90-100 90-100 90-100
2 90-95 90-95 85-95 90-100 85-95 90-100
3 85-90 88-95 85-90 85-90 85-95 90-100
4 90-100 90-100 85-90 90-100 95-100 95-100
5 95-100 95-100 90-100 90-100 95-100 95-100
6 90-100 90-100 85-90 85-95 90-100 90-100
7 90-100 85-95 85-95 85-95 95-100 95-100
8 95-100 95-100 90-100 90-100 85-95 85-90
9 95-100 95-100 90-100 90-100 85-95 95-100
10 85-95 85-95 85-95 85-95 85-95 85-95
11 85-95 95-100 90-100 85-95 90-100 90-100
12 95-100 95-100 85-95 85-90 85-95 85-95
13 85-90 90-95 85-95 85-100 85-90 85-90
14 85-90 87-95 90-100 90-95 90-100 90-100
 Lean Manufacturing- LMCS, Government of India

Pouring Temperature recorded

Sr# Pouring Temperature in degree Celsius

Heat no3 Heat no 4 Heat no.5
1 1359 1360 1359
2 1371 1368 1379
3 1366 1387 1377
4 1371 1359 1357
5 1356 1357 1350
6 1363 1362 1365
7 1349 1333 1357
8 1352 1352 1359
9 1326 1328 1349
10 1321 1324 1300
 Lean Manufacturing- LMCS, Government of India

Pouring Time
Sr# Pouring Time in seconds
Heat no-3 Heat no-4 Heat no-5
1 6.37 7.72 7.77
2 7.28 9.44 5.28
3 8.94 8.46 8.96
4 9.00 8.10 9.96
5 8.30 8.46 8.90
6 11.00 8.24 9.66
7 5.72 7.77 4.29
8 8.48 9.03 8.65
9 6.94 7.84 6.20
10 7.92 6.91 6.40
11 10.03 6.60 7.17
12 - 6.85 -
13 - 9.38 -
14 - 7.57 -
15 - 5.87 -
 Lean Manufacturing- LMCS, Government of India

The Rejection data recorded: Product Unipart-507

Heat Sand Swelling Slag Shift Cold Mold Shrink Total Total %
No Drop Metal Break rejection Production Rejection
15I33 3 - - 6 5 - 14 164 8.53
15I34 2 1 - 2 - 2 1 8 148 5.40
15I35 3 2 1 9 - 1 - 16 152 10.50
Total 8 3 1 17 5 3 1 38 468 8.11
% 21.05 7.90 2.63 44.7 13.16 7.90 2.63 100 - 81196 ppm
defect 3
 Lean Manufacturing- LMCS, Government of India

% Defects as per observed data of DoE

50

44.73
45

40

35

30

25
21.05
20

15 13.16
10 7.9 7.9
5 2.63 2.63
0

Sand drop Swelling Slag Shift Cold Metal Mold Break Shrink
Lean Manufacturing- LMCS, Government of India
 Lean Manufacturing- LMCS, Government of India

GCS
1500

1000

500 GCS

0
Heat no 3 Heat no 4 Heat no 5

Compact ability
60

40

20 Compact ability
0
Heat No.3 Heat No 4 Heat No.5
 Lean Manufacturing- LMCS, Government of India

The Pouring Time for Dabus

15

10 Heat no3
heat no.4
5
heat no 5
0

The Heat wise pouring Temperature

1400

1350 Heat no.3

1300 Heat no.4

Heat no 5
1250
 Lean Manufacturing- LMCS, Government of India
Possible Causes of Sand drop
Pattern Tooling
Environment Machine

Mould box maint M/c Maint. poor Improper draft

High Sand poorly. Loose fitments Sharp corners and radius/ narrow/ deep pockets
Temperature Alignment of M/c Worn out surface Protruding and overhang sections
Environment Compaction Improper parting line
Temperature Energy low Core print size
Humid & Hot condition No periodic inspection of patterns
Uneven compaction Draft on runners
Heavy vibrations of knockout
Compact. too high Mould Hardness low
Moulds exposed to dusty
environment Poor setting of M/c No cleaning
Sand Drop
Erosion -Pouring rate too high Low compactability High lump Content.
Ladle too above pouring basin Low Bentonite Poor sand quality
Too long pouring time High Lustrous Carb. Dry sand from Low level of Skill - no Training
Poor sand mixing hopper, mould Using mold boxes as foot rest
High dead clay
box and spillover during pouring
Late closing of moulds
Poorly developed
Clamping mould by bentonite Low core strength Hitting mold boxes by ladle during
hittingNo SOPs in place pouring
Moisture content Core mismatching Jumping of procedures for production
No close loop Low in moulds Sand mixture with numbers
Careless handling of moulds
for review of low compressive
No 1st heat approval Breakage of mould
deviations strength
Product sp. CTQ Fatigue-Higher rejection at last heat of shift
No opening Material
Method Man
of mould