New methodology for consistant decreasing scrap rates
Scrap problems are commonly attacked immediately by the most experienced foundry people, but in practice the problems appear again and again. It has been proven that the proposed methodology can solve the problems thoroughly, and then decrease the scrap rate substantially.The methodology consists of five steps: identification, search for the causes, analyzing the influences, corrective action and inspection of the result. The causes of a problem are divided into three groups: the basic ones (without them, the problem cannot happen), the secondary ones (they will influence the size/consequence of the problem) and the organizational/process ones (are not about the particular casting but the organization/process). Any potential solution will be related and evaluated towards all three groups. Any proposed corrective action must indicate also which new potential problem can be initiated. Every action has a positive and a negative effect. It must be considered if this negative effect can be tolerated. The inspection is set concerning the existing problem and the expected negative effect of the proposed solution. The corrective action is applied to a test piece and later to a test series. If both are meeting the requirements, the corrective action is accepted as valid and a new instruction is made. Then the process causes are investigated and solved. The technique to use also the process causes, combined with considering the negative effect of any proposed solution is the key for success. What seems to be a waste of time to consider them, showed them as a base for success.
methodology scrap rates causes identification analysing corrective action and inspection solution
Staf Henderieckx
GIETECH, BV, Rozenlaan 1 NL 4551 ET sas van Gent, The Netherlands
国际会议
The 11th Asian Foundry Congress(第11届亚洲铸造会议 AFC-11)
广州
英文
1-4
2011-11-12（万方平台首次上网日期，不代表论文的发表时间）