Optimization of foundry process using lean principles

Abstract

The development of foundry process is based on industrial practices and knowledge of the employees about the process. Most foundries are following trial and error system and few foundries have very less process control on rejection due to flaws and errors. It has become mandatory for foundries to produce error free products in optimal quality to survive in competitive market. Continuous improvement plays an important role in maintaining a cut-throat advantage in the existing industry environment. The implementation of lean tools in an industry will result in removal of non-value added process and helps to improve the overall efficiency. The lean principles are customized to improve the foundry processes in manufacturing of impeller casings. The value added and non value added activities are identified using a current state mapping in the existing process. A future state map is developed by reducing the non value added activities thus improving the overall efficiency.