Mainly analyzes and summarizes ZHY Casting optimized sand casting process from the aspects of product quality, scrap rate, product quantity, delivery date, cost, quality and safety risk, etc.
① Quality: the overall quality of steel castings has been greatly improved, especially the cracks and sand inclusion defects have been significantly reduced. The number of cracks has been reduced from 70 to less than 10; Sand inclusion decreased from 80 points to 20 points.
② In terms of waste products: the number of waste products is relatively significantly reduced, and the waste rate is reduced from 19% to 1.1%.
③ Process in production and delivery date: the process in production is reduced from 150 to 10. The delivery date is timely and there has never been any delay.
④ Quality and safety risk and feedback rate: after the product quality is improved, the quality risk is reduced, and there have never been safety accidents caused by product quality problems; The feedback rate decreased from 6.25% to 1.34%.
⑤ Cost: after the implementation of the new sand mold casting process, the cost of molding materials per ton of castings increased by 265 yuan, but the welding repair cost was saved by 226 yuan per piece; In terms of quality loss cost, the average cost saved per piece is 2672 yuan.
The above statistical analysis results show that the company has achieved remarkable results after optimizing the sand casting process of motor shell steel castings.