The present manufacturing scenario demands low quantity and high variety parts. Only through lean manufacturing, this target can be achieved. Just-in-Time manufacturing demands smaller production quantities which in turn mean more setup times (non-productive time). Companies should focus on reducing down time in order to remain competitive.
In this project work, die casting process and setup evaluation is carried out in Jeng Fong (JF DC H30) die casting machine. The “Rotor” casting is found as the bottle neck by studying the process in detail. With the help of pareto analysis the 4 major causes of more setup time were focused. They include nozzle change, coolant system assembly, parameter setting and inspection. The corrective actions were taken systematically to reduce the listed setup time. This included designing and manufacturing a new cooling system, inspection gauge, SOP for ease in setting of moulding parameters. 5S and kaizen activities were initiated in the company. Also training was given to the operators in SMED (converting of internal activities to external).
The project also focuses on reduction of manufacturing lead time of rotor part. Reduction of manufacturing lead time was brought into action by reducing the cycle time of the moulding process. With the help of new design of cooling assembly, the cycle time of cooling and spraying was brought down. Comparative study was done and the results were validated. Tools used for achieving the goals are SMED, 5S, SIPOC diagram, SOP, Poka-Yoke etc. The project implementation resulted in bringing down the setup time to 27% (from 69 min. to 19 min.) and manufacturing lead time reduction by 19% (70.5 hrs to 57.2 hrs).
SMED, SOP, Die Casting
