IMPLIMENTATION OF TOTAL QUALITY MANAGEMENT IN …Quality Control Tools Abhijeet B. Vante G.R.Naik...

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.

International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017

IJSRE Vol. 1 (3), March, 2017 www.ijsre.in 37

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


IJSRE Vol. 1 (3), March, 2017 www.ijsre.in Page 138

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



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



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



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.



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%



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



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



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.

REFERENCES

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2. A.p.more*, dr.r.n.baxi, dr.s.b.jaju, review of casting defect analysis to initiate the

improvement process, ijets, vol 2(4) 2011,292-295



3. Lakshamanan singaram, improving quality of sand casting using taguchi method and ann

analysis, international journal on design and manufacturing technologies, pages 01-05,

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9637 , 2015 , india

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8. Prasan kinagi, dr. R.g mencha “ development of quality in casting by minimizing

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IMPLIMENTATION OF TOTAL QUALITY MANAGEMENT IN …Quality Control Tools Abhijeet B. Vante G.R.Naik...

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