SAND CASTING PROCESS IMPROVEMENT USING LEAN PRINCIPLES

Abstract

Lean manufacturing is often seen as a set of tools that reduce the total cost and improve the quality of manufactured products. The lean management philosophy is one which targets waste reduction in every facet of the manufacturing business; however, only recently have studies linked lean management philosophies with improving environmental sustainability. These studies suggest that lean manufacturing is more than a set of lean tools that can optimize manufacturing efficiencies; it is a process and mindset that needs to be integrated into daily manufacturing systems to achieve sustainability. The foundry industry, as well as manufacturing in general, has significant challenges in the current regulatory and political climate with developing an economically and environmentally sustainable business model. Lean manufacturing has proven itself as a model for both economic sustainability and environmental stewardship. Several recent studies have shown that both lean and green techniques and “zero-waste” policies also lead to reductions in overall cost. This paper reviews the literature and some of the lean principles such as the Value Stream Mapping and Waste elimination by implementing 5S in the organization. This paper also aims at reducing lead time by eliminating stress relieving cycle with extended cooling of castings in the mould and stabilize the sand casting process by rationalization of the material grades.