J. Singh
D. Singh
H. Singh
S.Singh
Abstract
In the manufacturing industry, metal casting is one of the oldest basic metal forming process and most important to industry. The casting process incurs various defects leading to high casting reject levels and customer returns which have adverse effect on productivity, delivery performance, customer satisfaction and employee morale. In addition excessive rejection reduces yield, wastes valuable raw materials, wastes process time and involves management time in problem solving. This study was carried out to reduce the rate of rejection in casting and increase the profitability of the company using Layout Planning. Pouring temperature, Pouring time, Distance travelled by ladle and Strength of sand were key factors that contribute towards rejections. While moving through large distance, rejections were on high side. Whole process was studied and new layout was implemented with modified material handling techniques. This reduced the rejection by 6.53% and total savings to the company came out to be Rupees 589425 during first month after implementation and commissioning of new layout.
Keywords- Layout Planning, Manufacturing and Rejections.