Minimization of Rejection Rate and Lead Time in Medium Scale Foundry Industry by using Lean Manufacturing Practices

International Journal of Mechanical Engineering

© 2020 by SSRG - IJME Journal

Volume 7 Issue 11

Year of Publication : 2020

Authors : S. Nallusamy, Parthasarathi Chakraborty

10.14445/23488360/IJME-V7I11P101

How to Cite?

S. Nallusamy, Parthasarathi Chakraborty, "Minimization of Rejection Rate and Lead Time in Medium Scale Foundry Industry by using Lean Manufacturing Practices," SSRG International Journal of Mechanical Engineering, vol. 7,  no. 11, pp. 1-12, 2020. Crossref, https://doi.org/10.14445/23488360/IJME-V7I11P101

Abstract:

In the current globalization, production demand and customer satisfaction have progressively amplified with the development of a new technological process. This research's main objective is to reduce waste by reducing rejection in the manufacturing process and maintaining rejection percentages to meet company standards for specified departments. The industry's current rejection percentage was analyzed based on department wise and investigated the rejection rates for different products. After identifying the various causes of rejection in the current system, various methods are proposed to reduce the rejection level by identifying different defects. Different lean tools like Pareto analysis, cause and effect diagram, and VSM were applied to identify the defects and minimize rejection. The Pareto analysis was carried out to identify the major defects, and a cause and effect diagram was used to identify various methods to reduce the defects. Minitab statistical tool was used for Pareto analysis, and iGrafx is used for cause and effect diagram and also used for VSM to identify value-added, and non-value added activities. From the final results, it was noticed that the lead time was reduced by about 1000 minutes, and the rejection rate was reduced to less than 5%.

Keywords:

Foundry, Rejection, Lean Practices, Minitab, Productivity

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