Waste Assessment in an Indian Casting Industry: A step towards Lean Manufacturing
Abhyuday Singh Thakur1, Sagarkumar Patel2, Vivek Patel3

1Abhyuday Singh Thakur*, Dept. of Mechanical Engineering, Pandit Deendayal Petroleum University, Gandhinagar, India.
2Sagarkumar Patel, Dept. of Mechanical Engineering, G.H. Patel College of Engineering & Technology, Anand, India.
3Vivek Patel, Dept. of Mechanical Engineering, Pandit Deendayal Petroleum University, Gandhinagar, India.
Manuscript received on December 16, 2019. | Revised Manuscript received on December 22, 2019. | Manuscript published on January 10, 2020. | PP: 1861-1866 | Volume-9 Issue-3, January 2020. | Retrieval Number: C8686019320/2020©BEIESP | DOI: 10.35940/ijitee.C8686.019320
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© The Authors. Blue Eyes Intelligence Engineering and Sciences Publication (BEIESP). This is an open access article under the CC-BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)

Abstract: In today’s era of globalization, it is essential to ensure that Indian manufacturing industries like casting and metal-working industries which work on stringent conditions of varying customer demands and constant adhering to excellent quality standards are able to flourish in the fiercely competitive environment while keeping the production as economical as possible. Hence, the need arises for continuous improvement in the manufacturing phase of the product by assessing, minimizing, and eliminating wastes of any kind. This study adopts and implements a waste assessment model in a casting industry with the purpose of assessment of wastes and hence, proceed towards a leaner manufacturing set-up. Initially, the quantification of direct relationships between the seven types of wastes was done by forming a waste relationship matrix (WRM). Next, a waste assessment questionnaire (WAQ) consisting of 68 questions, was introduced for the allocation of wastes in the industry. The results of WRM and WAQ were integrated to obtain the ranks of the seven types of wastes in the industry, and it was found that waste of defects was the highest-ranked waste followed by wastes of inventory and overproduction. Process Activity Mapping (PAM) received the highest score (482.79) in the analysis done by Value Stream Analysis Tool (VALSAT), thus, it was chosen as the preferred tool in the current situation. The results of Failure Mode and Effect Analysis (FMEA) of various defects of casting indicated sand inclusions (432) and slag inclusions (336) as the defects having the highest Risk Priority Numbers (RPN). 
Keywords: Casting, Failure Mode, Lean Manufacturing, Risk Priority Number, VALSAT, Waste Assessment
Scope of the Article: Manufacturing Processes