Lean Production using Casting Simulation to Promote FTR Approach

Abstract

When the talk is about the green production, then intention is to develop a product with first-time-right approach. Foundry desperately needs such production system, as it provides wide range of products. Even the small errors in the inputs (concept, design, raw material, process, etc.) can lead to wasted outputs [1], and invite unwanted cost of reworking. Thus, it is of extreme importance to develop the castings with FTR (first time right) approach and tool used in casting the complicated design for such production system is known as casting simulation. Simulation ensures and optimizes every step of production, i.e., from designing to final product. In the present context, a case study of L-shaped casting is presented in which the junction suffers from several defects. Presently, to simulate the casting SOLIDCast software is used and work shows how simulation investigates and rectifies the errors prior to manufacturing.