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    Casting Blemishes and Supply Chain Relationship in Cast Iron Foundry

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    Casting Blemishes and Supply Chain Relationship in Cast Iron Foundry

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    Casting Blemishes and Supply Chain Relationship in Cast Iron Foundry

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    Vittal SB
    Detail of foundry

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    Elite Publications Journals

    Vol. 1(3), pp. 20-27, 05 May, 2015 International Journal of Research in


    ISSN Print : 2454-1435 © 2015 IJRMMAE Mechanical, Mechatronics and
    ISSN Online : 2454-1443 © 2015 IJRMMAE
    http://www.ijrmmae.in Automobile Engineering

    Casting Blemishes and Supply Chain Relationship in Cast


    Iron Foundry
    1 2
    N. Manikanda Prabu *, R.Suganthini Rekha
    1
    *Department of Mechanical Engineering, Nehru Institute of Engineering and Technology, Coimbatore,
    642105, E-Mail: mkp.thetrinity@gmail.com
    2
    Department of Mechanical Engineering, Dr. M.G.R. Educational and Research Institute University, Chennai,
    600095, E-Mail: rekha.mira24@gmail.com

    Received 10, April 2015 | Accepted 05, May 2015

    Abstract rejection rates and various other factors. This


    paper examines the relationship between
    In the competitive environment, foundry supply chain processes and quality as a key
    industries need to perform efficiently with role in supply chain management.
    minimum percentage of rejections there by
    reducing manufacturing cost. Foundries are Keywords: Supply Chain, Quality, key role,
    using state of art processes with the blemishes
    involvement of experienced and
    1 Introduction
    knowledgeable people but the experience and
    knowledge needs to be transformed for the Supply chain management (SCM) plays a vital
    growth of the industries. Some foundries are role in the growth of the industry, survival in
    working in a trial and error mode and get their the market, the production rate and the
    work done. Many foundries have very less dynamic interaction among the suppliers and
    control on the rejections since they are in the customers. SCM has been met with
    urgent need of meeting production targets and increased recognition during the last decade
    they ignore the rejections and salvage the both by academicians as well as practitioners.
    castings. They need to have effective quality SCM of a medium size cast iron foundry is
    control aiming for blemishes free castings taken and its system dynamics & simulation
    with minimum production cost. Strategic model is studied. System Dynamics (SD) is a
    decision makers need comprehensive models methodology whereby complex, dynamic and
    to guide them in efficient decision making that nonlinear interactions in the systems can be
    increases the profitability of the entire chain. analyzed and new structures and policies can
    The objective of the paper is to analyze the be designed to improve the system behavior.
    various blemishes from Cast Iron Foundry and SD modeling requires two types of flows, one
    remedies for the blemishes in a day to day is the physical flows, and another is the
    activity of an iron foundry. This paper information flow. In today’s highly
    presents the necessity of Quality in supply competitive marketplace a successful winner
    chain model of a medium size industrial iron is one who has the ability to satisfy the end
    foundry under different delay conditions, customer requirement. Foundry which was
    21 Int. J. Res. M.M.A.Engg, 2015, 1(3), 20 -27

    studied for this purpose is Ammarun Related work are summarized in Table 1.
    Foundries (AF). Established in the year
    1991,AF is a large Ferrous Foundry setup
    located in Southern part of India. Committed
    to high technology from the very start, AF
    producesGrey Iron -from low tensile to high
    tensile strength grades, DuctileIron -
    Pearliticthe Ductile Iron to various ranges of
    Ferrite Ductile Irons. Company also
    specializes in the production range of
    Automotive items like Brake Drums, Brake
    Discs, Hubs, Flywheels, Timing case, Oil
    sump and Gear Box Housings, Housings,
    castings for tractor application, Valve body
    assembly castings, Motor and pump castings,
    Compressor part castings, Castings for
    General Engineering Industries, Castings for
    textile machinery application. Company has
    secured various State and Central Government
    awards including ”BEST FOUNDRY
    AWARD” for the year 2003.AF is committed
    to green environment through deployment of
    cleaner technology, preservation of natural
    resources and committed to Corporate Social
    Responsibility. AF has developed alternate
    sources for power through wind mill project
    for self generation of electricity by installing
    two machines of 850KW capacity (Gamesa
    Make of Spain). AF has ongoing projects
    concerning preservation of rare materials used
    in the foundry. AF has successfully developed
    in-house,sand reclamation process wherein
    silica sand is recovered from used CO2
    bonded mould sands. The company has put up 3 Foundry Processes
    a working model ofthe same in house.The
    Foundry is certified to Environment The output of the foundry is in the range of
    Management System ISO 14001:2004 1500 tons of good castings per month and out
    standards by Det Norske Veritas AS, of which 850 Tons from SINTO high pressure
    Netherlands. molding line, 600 Tons from conventional
    ARPA molding line and 50 Tons by hand
    2 Related Works molding. Table 2 shows list of main
    22 Int. J. Res. M.M.A.Engg, 2015, 1(3), 20 -27

    equipments installed in the foundry and Fig. 1 laboratory to monitor foundry sand quality on
    shows the foundry process in detail. a continual basis.

    4 Process Views of Supply Chain

    There are two different ways to view the


    processes performed in a supply chain:

    Cycle View: processes are divided into serious


    of cycles, each performed at the interface
    between two successive stages of a supply
    chain as in Fig.2.

    Spectro-meter ARL Thermo electron Push/Pull View: Pull processes are initiated by
    Corporation Switzerland make is equipped to a customer order, whereas push processes are
    analyze 20 elements with metallographic initiated and performed in anticipation of
    image analyzer to precisely to estimate the customer orders as in Fig.3.
    various micro structural constituents.
    Mechanical testing laboratory equipped to 5 Types of Blemishes and Remedies
    estimate tensile strength, hardness and sand
    23 Int. J. Res. M.M.A.Engg, 2015, 1(3), 20 -27

    The molding process causes blemishes in they can be used to solve majority of quality
    castings which may be eliminated with best related issues.
    molding practices or repaired using method
    They are :
    such as welding and other metal working
    processes. Some of the major blemishes in 1Check sheet
    sand casting production are listed in Table 3.
    2Brain Storming

    3Fish Bone diagram

    4Control chart

    5Histogram

    6Scatter diagram

    7Pareto chart

    The data collected from AF for actuator part


    no.1701 (AF-5092) are used for analysis. The
    castings are produced in automatic molding
    machine where the initial settings are
    important. Check sheet, brain storming, fish
    bone diagram, control chartand histogramare
    used for the analysis.

    6.1Check Sheet

    The rejection data was obtained from the


    foundry and placed in a tabulated form for the
    convenience to use and understand. Rejection
    data sheet are large data sheet showing all the
    information about the rejected items. A
    simplified data from the total rejection sheet is
    represented in the following

    6 Methodology
    total poured quantity and total rejection,
    The Seven Basic Tools of Quality is a molding blemishes, melting blemishes,
    designation given to set graphical techniques fettling blemishes and patterns blemishes
    and most helpful for troubleshooting issues during the period.
    related to quality. The tools are suitable for
    people with little knowledge on statistics and
    24 Int. J. Res. M.M.A.Engg, 2015, 1(3), 20 -27

    6.2 Brain Storming

    The brain storming session was conducted for


    finding different causes behind the blemishes
    and identifying the main causes and
    responsibility for the maximum damage. It
    consists of a group of members from different
    foundry departments which includes pattern
    shop manager, quality manager, melting
    supervisor, molding supervisor, fettling
    supervisor, core shop supervisor and high
    level management members and also shop
    floor members. After brain storming session,
    it was concluded that insufficient number of
    air vents are major cause for the blemishes
    bend and decided to increase the number of air
    vents from two to six considering the shape
    and size of the casting.

    Table 5 helps in analyzing the sand inclusion


    blemishes with feedback from various
    departments. Results obtained are placed in
    tabulated form. Rating is from 0 to 5, higher is
    the number in rating more is the severity.
    6.3Fish Bone Diagram
    strength yes yes No No No 3
    The root – cause analysis is carried out for one
    of the repeated blemishes of sand inclusion e
    as per Fig.4.
    25 Int. J. Res. M.M.A.Engg, 2015, 1(3), 20 -27

    Control chart for rejections was plotted by


    collecting the details of the rejections with two
    numbers of air vents (before) and with six
    numbers of air vent (after). Table-6 shows the
    details of rejections before and after. The
    castings are produced by using automatic
    molding machine and the rejection percentage
    is in the decreasing order as per Table-5. The
    control charts are plotted as per details of
    Table-4 and the Fig.3 gives the impact of
    blemishes and the percentage of rejections in
    the decreasing order.

    6.5 Histogram

    The histogram shows the impact of blemishes


    and the percentage of rejections in the
    decreasing order as in Fig.6.
    26 Int. J. Res. M.M.A.Engg, 2015, 1(3), 20 -27

    7 Results and Discussion 8 Conclusion

    A study and discussion with all the This paper considered a simple supply chain
    stakeholders showed that insufficient number model, where the relationships and various
    of air vents was the major cause for the parameters were identified. Fig 7 shows the
    blemishes. Based on the shape and size of the supply chain linkages in jobbing foundry
    casting, the number of vents were increased to processes. The rejection due to casting
    six and the results show that this has a positive blemishes can be reduced with effective
    effect. Table5 shows clearly the rejection supply chain linkages between pattern dept.,
    percentage before and after providing molding dept., and melting dept., to satisfy the
    additional air vents. The introduction of this external customer and with feedback from the
    method over some of the major blemishes are: external customer, the rejections can be
    bend blemishes due to molding reduced from further reduced with continuous improvement.
    1.234% to 0.942%, blow blemishes reduced This work has allowed exploring and
    from 0.218% to 0.13%, mold broken reduced understanding the complex behavior of
    from 0.079% to 0.029% and there is no molding sand, core sand effect to the
    blemishes due to pattern. Due to this production of iron castings and its rejections,
    improvement the supply chain between good customer satisfaction, thereby improving
    internal customers and external customers the supply chain efficiency. It is useful to take
    improved as the percentage of overall the decisions by studying the graphs with
    rejection got reduced from 2.874% to 2.057%. regard to the products and its quality with
    respect to blemishes. It is useful to make
    Fig. 7 Supply Chain Linkages in Foundry inventory policies and by taking the yearly
    Processes demand, one can able to estimate the casting
    rejections, sand level and core level and also
    the rate of production.

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