Execution of Systematic Lean Approach for Reduction of Defects in Foundry Division of Manufacturing Industry

In current global scenario, production demand and customer satisfaction has progressively amplified with the development of new technological process. The main objective of this research are to reduce waste by reducing rejection in manufacturing process and to maintain rejection percentage to meet company standards for specified departments. The current rejection percentage of the industry was analysed based on department wise and also investigated the numbers of rejection for different products. After identifying the various causes for rejection in the current system, various methods are proposed to reduce the rejection level by identifying different types of defects. Different lean tools like Pareto analysis, cause and effect diagram and Response Surface Plot (RSP) were applied to identify the defects and also to minimize the rejection level. Pareto analysis was carried out to identify the major defects and cause and effect diagram was used to identify various methods to reduce the defects. ANOVA statistical tool, which was used for RSP is used for finding out the percentage of defects. From the final results, it was noticed that the rejection rate was reduced to less than 4.95%.