Competitiveness Through Defect Mitigation Professed in a Low Pressure Die Casting Facility

Through this present work the author attempts to draw manufacturers’ attention to the urgency of Defect mitigation, as a prelude to achieving organisational competency. No manufacturer must have the licence to create defects, for the scrap generation comes with attendant costs which are only paid for by the society, the government and the organizations doing business with the said producer. The present work builds over a case study undertaking experimentation, in Low Pressure Die Casting (LPDC) using Lead, facilitated by analysis with statistical techniques using ANOVA and DOE. The reporting of results is largely notional and directs principally towards improvement of organisation’s manufacturing competency. Use of a three pronged structured methodology involving Strategic, Operational and Tactical stimuli is illustrated, interspersed with another triple step action points viz: setting your house in order, comprehending right correction stimulus and then detailing the management process for consistent performance. The exercise helped reduce shell core rejection to zero, entailing 25 % capacity enhancement in addition to the bad cores converted to good ones. This was effected by reduction of Hopper time for stand filling and Box time for silica sand polymerization