Improving Recovery Rate during Aluminium Casting Process by Eliminating Bends using Quality Tools

Extrusions (or profiles) made of aluminium have repeatedly demonstrated their superiority in terms of effectiveness, durability, and efficiency in a variety of applications, including consumer goods, transportation, electronics, engineering and construction. Aluminium extrusions provide advantages unequalled by other materials and processes where time, cost, and process reliability are crucial considerations for the manufacturer. The objective of this study is to use data obtained in the industry to characterize and quantify the bending defect that occur during the casting process. During Aluminium casting process, the quality of the completed product was significantly reduced by bending defect as they result in higher production costs and a higher percentage of scrap. To locate the fundamental causes, correct likely deviations, and make major changes, a variety of quality techniques are used, including Brainstorming, 4W-1H Analysis, Ishikawa diagram, 5-WHY Analysis and Preventive / Corrective action methods. The main goal of employing these tools is to give operators and supervisors the right indications that govern the production process and help them locate the crucial casting variables or other factors that are to blame for excessive waste, errors, and decrease in productivity. The findings showed that Log Bend makes up a sizable portion of the overall analyzed flaws, proving the necessity of tracking this issue. The present study revealed that a number of factors have a role in the development of these flaws. To lower the rejection rate and achieve the internal rejection objective, certain action strategies have been put up. The outcomes could serve as a benchmarking tool for other extrusion facilities of similar nature.