During manufacturing of hot cast product
20% of the mixture curing in the packaging generated volume shrinkage, dents
and deformations which rendered the product unavailable for sale, thus being
subject to removal.
The production process as well as raw
materials, equipment and technologies being used were all analysed. The source
of this problem was determined, being too high temperature difference between
the mixture being cast and the storage packaging. By raising the packaging
temperature to a room temperature, the off spec product ratio dropped to 4%.
Due to eliminate such problem, a remedy system was developed allowing to get
rid of this issue.
The off spec product ratio, being a waste product, was reduced to zero
The company generated savings (waste reduction, no utilisation costs) and increased production efficiency (no need to make larger product batches);