Shubham Sharma

Vikas Ucharia

Chetan Sharma

Rupinder Singh Kanwar

Abstract

Casting is one of the direct methods of manufacturing the desired geometry of the component. Casting defects result in increased unit cost. The defects need to be diagnosed correctly for appropriate remedial measures; otherwise new defects may be introduced. Unfortunately, this is not an easy task, since casting process involves complex interactions among various parameters and operations related to metal composition, methods design and molding etc. Check sheets help to study all the defects easily. Pareto chart and Cause and Effect Diagram are very useful to identify and classify the reasons which are responsible for defective casting production and lower productivity of organization. While Ishikawa's diagram of cause & effect or “fish bone” diagram makes possible identification of sources of problems formation, helps qualify a sequence. Rejection data is analyzed using seven quality tools. Analysis helps to sort out the major causes which are contributing for over 80% of the problems.

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