Title: Improvement of overall equipment effectiveness for manufacturing of ductile iron casting: a case study

Authors: Pravin Jadhav; Sharadchandra Patil; Satyajit Ingawale; Aditi Aljapurkar

Addresses: Karmaveer Bhaurao Patil College of Engineering, Satara, India ' Karmaveer Bhaurao Patil College of Engineering, Satara, India ' Karmaveer Bhaurao Patil College of Engineering, Satara, India ' Dr. D.Y. Patil B-School Tathawade, Pune, India

Abstract: A case study is taken in ductile iron sand casting foundry to implement various methods to improve manufacturing performance and calculate overall equipment effectiveness (OEE). The OEE is improved in foundry and machine shop for a flange by modification in casting and total productive maintenance (TPM) implementation. Various defects like shrinkage, sand and mould crack are observed in the casting. Among that, shrinkage (46.76%) has maximum contribution towards the rejection of the flange. The new system is developed and the OEE of the foundry and machine shop are calculated. OEE in the foundry is improved from 72.01% to 77.67%. The relative improvement in OEE is about 7.86% in the foundry. After implementing TPM, 5S in the machine shop, it is observed that machine OEE has been increased from 60.46% to 64.63%, and the relative improvement is about 6.90%.

Keywords: overall equipment effectiveness; OEE; availability; performance; quality; ductile iron casting; total productive maintenance; TPM; foundry; machine shop; casting; shrinkage.

DOI: 10.1504/IJPQM.2023.135886

International Journal of Productivity and Quality Management, 2023 Vol.40 No.4, pp.469 - 490

Received: 30 Jul 2021
Accepted: 19 Jan 2022
Published online: 09 Jan 2024 *

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