Implementation of lean initiatives to minimise defects in a forging enterprise

Ajit Kumar Sahoo, N.K. Singh and M.K. Tiwari

International Journal of Productivity and Quality Management, 2007, vol. 2, issue 3, 322-346

Abstract: This research addresses the implementation of the lean philosophy in a forging environment where hot forging operations are performed. In this paper, the authors have kept their prime focus on reducing various forging defects such as under-filling, overlap, etc. in the connecting rod production flow line. After giving a brief on the lean paradigm, a systematic approach is suggested for the implementation of the lean manufacturing principles. An analysis of the various critical process parameters has been carried out with the help of Taguchi's method of Design of Experiment (DOE). To save time and to make the analysis more precise and cost effective, a simulation exercise using finite element analysis is also performed. Furthermore, the results obtained are tested on the shop floor and it is realised that the defect levels have reduced significantly. Future courses of improvement are recommended. Consequently, the idea of an automatic billet flow control mechanism between the furnace and the press with a temperature indicator is advocated.

Keywords: lean manufacturing; forging defects; Taguchi; design of experiment; finite element analysis; orthogonal array; analysis of variance; ANOVA; hot forging; quality management. (search for similar items in EconPapers)
Date: 2007
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