How Continuous Improvement Boosts Foundry Operations

As highlighted in Foundry Magazine’s article Continuous Improvement in Foundry Processes,” the ISO 9001:2008 standard plays a crucial role in modern foundries by emphasizing a process-based approach to quality management and profitability. Despite technological advancements in machinery, chemical binders, and simulation software, many foundries still lose 5–10% of revenue due to scrap and rework. This underscores the importance of adopting continuous improvement practices to maintain optimal process conditions.

Continuous improvement involves methodical process enhancements that are evaluated over time to ensure meaningful progress. To achieve this, foundries must first map out their core processes, including patternmaking, molding and coremaking, metal melting and pouring, and finishing. The steps outlined below provide a roadmap for effective continuous improvement:

  1. Process Mapping: Develop a high-level diagram to identify and name each core process.
  2. Data Collection: Use Excel worksheets to document product codes, defect types, and costs related to scrap and rework. Tools like pivot tables help pinpoint which parts and defects cause the most financial loss.
  3. Pareto Chart: Identify common defects contributing to the highest loss using a Pareto chart to prioritize improvement efforts.
  4. Defect Attribution: Link specific defects to their corresponding processes (e.g., shrinkage defects in patternmaking, sand burn-in during coremaking, and quench cracks during heat treatment).
  5. SIPOC Diagrams: Create SIPOC diagrams (Suppliers, Inputs, Process, Outputs, and Customers) for each subprocess to measure performance metrics accurately. Continuous improvement requires collecting and monitoring relevant data over set timeframes (e.g., daily, weekly, monthly).

Choosing the Right Metrics:
Selecting appropriate performance metrics, such as defects per million (PPM), is key to benchmarking quality. A common goal is to maintain a PPM of 3,000, meaning no more than three defective castings per 1,000 shipped. Foundries can implement monthly targets and continuously refine their processes to improve performance.

By following these structured steps, foundries can enhance process efficiency, reduce costly scrap and rework, and meet the high-quality standards expected in the metalcasting industry.

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Article with all rights reserved, courtesy of Foundry Magazine.