Title: Implementation of lean initiatives to minimise defects in a forging enterprise

Authors: Ajit Kumar Sahoo, N.K. Singh, M.K. Tiwari

Addresses: Department of Manufacturing Engineering, National Institute of Foundry and Forge Technology, Ranchi-834003, India. ' Department of Forge Technology, National Institute of Foundry and Forge Technology, Ranchi-834003, India. ' Department of Forge Technology, National Institute of Foundry and Forge Technology, Ranchi-834003, India

Abstract: This research addresses the implementation of the lean philosophy in a forging environment where hot forging operations are performed. In this paper, the authors have kept their prime focus on reducing various forging defects such as under-filling, overlap, etc. in the connecting rod production flow line. After giving a brief on the lean paradigm, a systematic approach is suggested for the implementation of the lean manufacturing principles. An analysis of the various critical process parameters has been carried out with the help of Taguchi|s method of Design of Experiment (DOE). To save time and to make the analysis more precise and cost effective, a simulation exercise using finite element analysis is also performed. Furthermore, the results obtained are tested on the shop floor and it is realised that the defect levels have reduced significantly. Future courses of improvement are recommended. Consequently, the idea of an automatic billet flow control mechanism between the furnace and the press with a temperature indicator is advocated.

Keywords: lean manufacturing; forging defects; Taguchi; design of experiment; finite element analysis; orthogonal array; analysis of variance; ANOVA; hot forging; quality management.

DOI: 10.1504/IJPQM.2007.012453

International Journal of Productivity and Quality Management, 2007 Vol.2 No.3, pp.322 - 346

Available online: 14 Feb 2007 *

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