“Productivity Improvement of Casting Industry Using Kaizen and 5S Techniques – A Case Study on Ebenezer Alloys”

Abstract

Nowadays, manufacturing industries all over the world are interested in profit maximization with maintaining
their level of quality and increasing their market share in the competitive market. The purpose of our project is to study
the sand casting process, casting defects and metal loss in various operation carried out during the casting process in
foundry. Sand casting process is the simplest process and most widely used in the foundry to produce the different range
of component. However it involves lot of parameters to control for the production of a good quality component. The
casting industry in our case study faces the problem of defects and metal loss which decreases the quality of the
component and increases the cost. To improve their productivity is a challenging task and for that we will implement the
quality techniques such as “Kaizen” and “5S” with as minimum amount of expense as possible and with maximum
benefits for the industry. We will also work on changing the plant layout of the industry because the company is not
properly utilizing their plant resources with the present layout. We will also give some mould box design suggestions in
order to improve quality and yield of their castings and reduce their metal loss and thereby improving their productivity.
Hence our overall aim is to increase the productivity of industry.