A REVIEW ON REDUCING CASTING DEFECTS AND IMPROVING PRODUCTIVITY IN A SMALL SCALE FOUNDRY USING DMAIC APPROACH

Casting has various processes like Pre casting Processes, pattern making, core making, molding and mold assembly making, Casting Processes, furnace charging, melting, holding and pouring, and Post casting Processes, shakeout, inspection and dispatch etc. In India there are many foundry have followed conventional and manual operations. Mold shifting, Crushing, Lower Surface finish, Shrinkage, Porosity, Cold shut and Extra material are common casting defects due to these manual operations. Improve quality and productivity by apply seven quality control tools technique sum of the known problems which are face in the small scale to top level scale of industries. This review paper presents all data of manual sand casting operations and defects leads to rejection and also represents analysis of these defects with seven quality control tool.