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“If only my foundry knew what it knows …”: A 7Epsilon perspective on root cause analysis and corrective action plans for ISO9001:2008

HMd Roshan, Cinzia Giannetti, Meghana R. Ransing, Rajesh Ransing Orcid Logo

World Foundry Congress 2014

Swansea University Author: Rajesh Ransing Orcid Logo

Abstract

The famous quotes of a former Chairman, president and CEO of Texas Instruments and Chairman of HP “if only we knew what we know” are very much applicable to the foundry industry. Despite the fact that many advances have been made in the field of foundry technologies relating to simulation software,...

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Published in: World Foundry Congress 2014
Published: 2014
URI: https://cronfa.swan.ac.uk/Record/cronfa24479
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Despite the fact that many advances have been made in the field of foundry technologies relating to simulation software, moulding machines, binder formulation and alloy development, poor quality still remains a major issue that affects many foundries not only in terms of lost revenues but also contributing to negative environmental impacts. On an annual casting production of 95 million tonnes, assuming that on average 5% defective castings are produced with a production cost of 1.2&#x20AC; per kg for ferrous alloys, the foundry industry is losing 5.7 billion &#x20AC;, producing landfill waste well in excess of two million tonnes and releasing just under two million tonnes of CO2 emissions. Foundries have vast proportion of knowledge that is waiting to be tapped, documented, shared and reused in order to realise the saving potential of 5.7 billion &#x20AC; per year. 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In this paper a penalty matrix approach is described for discovering main effects and interactions among process factors and responses by analysing data collected during a stable casting process. Through a practical cases study it is shown how this technique can be used as an effective tool in the root cause analysis of nonconforming products in the implementation of ISO9001:2008 requirements for continual improvement. In addition some practical aspects concerning the development of a knowledge management repository to store and retrieve foundry process knowledge are discussed. 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spelling 2016-08-04T14:11:19.9917199 v2 24479 2015-11-18 “If only my foundry knew what it knows …”: A 7Epsilon perspective on root cause analysis and corrective action plans for ISO9001:2008 0136f9a20abec3819b54088d9647c39f 0000-0003-4848-4545 Rajesh Ransing Rajesh Ransing true false 2015-11-18 MECH The famous quotes of a former Chairman, president and CEO of Texas Instruments and Chairman of HP “if only we knew what we know” are very much applicable to the foundry industry. Despite the fact that many advances have been made in the field of foundry technologies relating to simulation software, moulding machines, binder formulation and alloy development, poor quality still remains a major issue that affects many foundries not only in terms of lost revenues but also contributing to negative environmental impacts. On an annual casting production of 95 million tonnes, assuming that on average 5% defective castings are produced with a production cost of 1.2€ per kg for ferrous alloys, the foundry industry is losing 5.7 billion €, producing landfill waste well in excess of two million tonnes and releasing just under two million tonnes of CO2 emissions. Foundries have vast proportion of knowledge that is waiting to be tapped, documented, shared and reused in order to realise the saving potential of 5.7 billion € per year. This ambitious goal can only be achieved by developing effective knowledge management strategies to create, retain and re-use foundry and product specific process knowledge whilst supporting a smart and sustainable growth strategy. This is the focus of 7Epsilon (7ε), an innovative methodology led by Swansea University along with a consortium of European universities and research organisations. At the core of 7ε capabilities is casting process optimisation which is defined as a methodology of using existing casting process knowledge to discover new process knowledge by studying patterns in data 1. According to the 7ε terminology, casting process knowledge is actionable information in the form of a list of measurable factors and their optimal ranges to achieve a desired business goal 1, 2. In this paper a penalty matrix approach is described for discovering main effects and interactions among process factors and responses by analysing data collected during a stable casting process. Through a practical cases study it is shown how this technique can be used as an effective tool in the root cause analysis of nonconforming products in the implementation of ISO9001:2008 requirements for continual improvement. In addition some practical aspects concerning the development of a knowledge management repository to store and retrieve foundry process knowledge are discussed. A template to document and structure foundry and product specific process knowledge is proposed so that knowledge can be stored and retrieved more efficiently by process engineers and managers with the final aim to improve process operations and reduce defects rates, taking a significant step towards achieving zero defect manufacturing. Conference Paper/Proceeding/Abstract World Foundry Congress 2014 7Epsilon, Casting Process, ISO9001:2015, Knowledge Discovery, Knowledge Representation, Process Improvement, Six Sigma, Total Quality Management 31 12 2014 2014-12-31 COLLEGE NANME Mechanical Engineering COLLEGE CODE MECH Swansea University 2016-08-04T14:11:19.9917199 2015-11-18T13:16:25.7479874 Faculty of Science and Engineering School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering HMd Roshan 1 Cinzia Giannetti 2 Meghana R. Ransing 3 Rajesh Ransing 0000-0003-4848-4545 4 0024479-18112015131801.pdf 7Epsilon_case_study_to_satisfy_requirements_of_clause_6-1-2_and_7-1-6_of_ISO9001_2015_WFC2014_UKExchange_paper.pdf 2015-11-18T13:18:01.9530000 Output 2161775 application/pdf Accepted Manuscript true 2015-11-17T00:00:00.0000000 false
title “If only my foundry knew what it knows …”: A 7Epsilon perspective on root cause analysis and corrective action plans for ISO9001:2008
spellingShingle “If only my foundry knew what it knows …”: A 7Epsilon perspective on root cause analysis and corrective action plans for ISO9001:2008
Rajesh Ransing
title_short “If only my foundry knew what it knows …”: A 7Epsilon perspective on root cause analysis and corrective action plans for ISO9001:2008
title_full “If only my foundry knew what it knows …”: A 7Epsilon perspective on root cause analysis and corrective action plans for ISO9001:2008
title_fullStr “If only my foundry knew what it knows …”: A 7Epsilon perspective on root cause analysis and corrective action plans for ISO9001:2008
title_full_unstemmed “If only my foundry knew what it knows …”: A 7Epsilon perspective on root cause analysis and corrective action plans for ISO9001:2008
title_sort “If only my foundry knew what it knows …”: A 7Epsilon perspective on root cause analysis and corrective action plans for ISO9001:2008
author_id_str_mv 0136f9a20abec3819b54088d9647c39f
author_id_fullname_str_mv 0136f9a20abec3819b54088d9647c39f_***_Rajesh Ransing
author Rajesh Ransing
author2 HMd Roshan
Cinzia Giannetti
Meghana R. Ransing
Rajesh Ransing
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container_title World Foundry Congress 2014
publishDate 2014
institution Swansea University
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hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering
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description The famous quotes of a former Chairman, president and CEO of Texas Instruments and Chairman of HP “if only we knew what we know” are very much applicable to the foundry industry. Despite the fact that many advances have been made in the field of foundry technologies relating to simulation software, moulding machines, binder formulation and alloy development, poor quality still remains a major issue that affects many foundries not only in terms of lost revenues but also contributing to negative environmental impacts. On an annual casting production of 95 million tonnes, assuming that on average 5% defective castings are produced with a production cost of 1.2€ per kg for ferrous alloys, the foundry industry is losing 5.7 billion €, producing landfill waste well in excess of two million tonnes and releasing just under two million tonnes of CO2 emissions. Foundries have vast proportion of knowledge that is waiting to be tapped, documented, shared and reused in order to realise the saving potential of 5.7 billion € per year. This ambitious goal can only be achieved by developing effective knowledge management strategies to create, retain and re-use foundry and product specific process knowledge whilst supporting a smart and sustainable growth strategy. This is the focus of 7Epsilon (7ε), an innovative methodology led by Swansea University along with a consortium of European universities and research organisations. At the core of 7ε capabilities is casting process optimisation which is defined as a methodology of using existing casting process knowledge to discover new process knowledge by studying patterns in data 1. According to the 7ε terminology, casting process knowledge is actionable information in the form of a list of measurable factors and their optimal ranges to achieve a desired business goal 1, 2. In this paper a penalty matrix approach is described for discovering main effects and interactions among process factors and responses by analysing data collected during a stable casting process. Through a practical cases study it is shown how this technique can be used as an effective tool in the root cause analysis of nonconforming products in the implementation of ISO9001:2008 requirements for continual improvement. In addition some practical aspects concerning the development of a knowledge management repository to store and retrieve foundry process knowledge are discussed. A template to document and structure foundry and product specific process knowledge is proposed so that knowledge can be stored and retrieved more efficiently by process engineers and managers with the final aim to improve process operations and reduce defects rates, taking a significant step towards achieving zero defect manufacturing.
published_date 2014-12-31T03:29:02Z
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