Assignment #1

Metrology and Quality Assurance

Title:
Eight forms of waste in a foundry shop

Submitted To:
DR. MUHAMMAD ARIF

Submitted By:
USAMA MANZOOR

Registration No.
2019-UET-NFC-FD-MECH-30

DEPARTMENT OF MECHANICAL ENGINEERING

NFC Institute of Engineering and Fertilizer Research

Faisalabad
 8 Types of Waste in Foundry Shop
Waste:
Anything that doesn’t add value to a product is defined as waste. Waste is any cost that paid in a
process that does not benefit the customer. Lean manufacturing is a successful way for eliminating
waste from manufacturing processes.

8 of waste in foundry shop are given below:

We use an abbreviation “DOWNTIME” for eight type of wastes in foundry shop. Every single
letter represents a waste. Following are the wastes of foundry shop.

o Defects
o Overproduction
o Waiting
o Non-utilized talent
o Transportation
o Inventory
o Motion
o Extra processing
1. Defects
Defect is a condition after which the material is thrown out (scrap) or need to be rework. It is an
undesirable condition which effects the requirements of customer. In foundry shop there are many
defects in which some of them are given below.

 Porosity
When cast metal solidifies in a mold, it can’t hold as much gas as it does in liquid form, so it
releases it due to which our material becomes porous. That is part of the reason molds are
permeable, to allow gas to escape.

How to Prevent Porosity:

Avoid pinholes, blowholes, and open holes by making sure the molding sand is dry and permeable.
It should be noted that the coarser sand is, the more permeable it is. Even using sand that is too
fine can prevent optimal permeability. Additionally, sand molds that have been rammed too much
lose their permeability, so it’s important not to overdo it. Make sure that molds and cores are dry
before use and stored under dry conditions as well, and be sure that there’s enough venting in the
molds to allow gases to escape.

 Shrinkage Defects

Shrinkage is also a defect which appears because metal alloys shrink as they cool. Due to this
effect our target value can’t be achieved.

How to Prevent Shrinkage Defects:

Problems with continuous flow at the right temperature (results in uneven solidification) can be
lessened by ensuring a continuous, even supply of liquid metal into the molds. This can be
accomplished by using a runner and gate system with risers to supply the molten metal, which
involves channels for the metal to flow through into the mold (the running system) and reservoirs
of liquid metal on top of the mold (also known as risers) to fill in where the metal shrinks.

 Material Defects

Material defects are caused by the material which is mold related. Means the material that we are
using for molding is defected.
How to Prevent Mold Material Defects:

Ensuring molds receive enough ramming to hold the molten metal is an effective way to cut down
on all of these problems, as well as making sure the metal being poured isn’t too hot. However, if
that doesn’t work there are other methods of fixing these issues that vary from defect to defect.

2. Overproduction
When components are produced before they are required by the next downstream process,
overproduction occurs. Overproduction is a waste because you are making the components that
are not required.

Causes of Overproduction include:

 Unreliable process
 Unstable production schedules
 Inaccurate forecast and demand information
 Customer needs are not clear
 Poor automation

How to prevent them:

We prevent by using JIT tool in which component and material are delivered just before they are
needed. We find cycle time and then we find takt time and equal them. We also used MTO (Make-
to-Order) which is how to reasonably arrange the production plan has become a very common and
urgent problem for enterprises’ managers to improve inner production reformation in the
competitive market environment.
3. Waiting
Waiting involves delays to process steps, often extending customer lead-time. Waiting is the
opposite of overproduction. However, it can be eliminated with many of the same remedies.
Waiting is often the result of poor process design and can be addressed through proper
measurement of takt time and the creation of standard work.

How to prevent them:

It can be prevent by the implementation of following points which are given blew.

 planned downtime or Idle equipment

 decrease long or delayed set-up times
 good process communication
 process control
 Producing to a forecast
 Idle equipment

4. Non-utilized talent
Not fully utilized people represents the waste of talent present in many organizations. Because
operators are close to their processes daily, they can often recognize problems or opportunities that
staff or superiors just don’t see, but the workers may never be asked for their input. This waste
was added to allow organizations to include the development of staff into the lean ecosystem. As
a waste, it may result in assigning employees the wrong tasks or tasks for which they were never
properly trained. It may also be the result of poor management of communication.
How to prevent them:
It can be prevent by the implementation of following points which are given blew.

 communication
 Identify Failure to involve people in workplace design and development
 Identify lack of or inappropriate policies
 complete measures
 good management
 good team training

5. Transport
Transportation deals with unnecessary movement of products. From a customer perspective,
transport adds NO value to the product. In fact, transportation can sometimes even reduce value.
It may also result from poorly designed processes or processes that have not been changed or
updated as often as required.

How to prevent them:

Value stream mapping and partial or full changes in factory layout can reduce transportation waste.
This is a full documentation of all aspects of the production flow and not just the mapping of a
specific production process. This results in changes to reduce or eliminate transportation waste.
It can also prevent by the implementation of following points which are given blew.

 good layouts – small distance between operations

 small material handling systems
 small Batch sizes
 decrease multiple storage facilities
 design good production systems

6. Inventory
Inventory may not seem like a bad thing. After all, a supplier never wants to be in the position of
not being able to meet customer demand. It may also signal a broken or poorly designed process
link between manufacturing and purchasing/scheduling.

How to prevent them:

It may also signal a broken or poorly designed process link between manufacturing and
purchasing/scheduling.so it can be prevent by Purchasing, scheduling and forecasting can have a
version of standardized work in the form of defined minimums and maximums and order points
that are mapped to the process flow and takt time. Purchasing raw materials only when needed
and reducing WIP and eliminating or narrowing the definition of “safety stock” will reduce this
type of waste. It can also prevent by the implementation of following points which are given blew.

 Don’t Overproduction of goods

 Don’t Delays in production or ‘waste of waiting’
 Decrease Inventory defects
 Don’t excessive transportation
7. Motion
Motion involves movement by people. Even small non-value-added motion can be very costly. It
may also include excess physical motion such as reaching, lifting and bending. All unnecessary
motion results in non-value-added time and increases cost.

How to prevent them:

Process mapping should include facility layout and optimized workplace design that includes
analysis of the distance of motion within the space as well as the location of parts, supplies and
tools within the space as well. As an effective process map is developed, proper utilization of the
space can be captured with well-designed and documented standard work. It can also prevent by
the implementation of following points which are given below.

 good workstation layout

 good production planning
 good process design
 don’t Shared equipment and machines

8. Extra processing
Excess processing might be extra steps in a process, unnecessary customization, inefficient
routings and other things not necessary or valued by the customer. This could be related to
management or administrative issues such as lack of communication, duplication of data,
overlapping areas of authority and human error. It may also be the result of equipment design,
inadequate job station tooling or facility layout.
How to prevent them:
Process mapping is a lean waste elimination tool that helps define an optimized workflow that can
eliminate over processing. As a key method within lean production, process mapping is not limited
to the performance of production tasks. It also includes reporting, signoff and document control.
It can also prevent by the implementation of following points which are given blew.

 communication
 understand your customers’ needs
 decrease human error
 fast the approval process or excessive reporting