After the above improvement measures are taken, the waste of valve castings and the statistics of defect types are shown in Table 1 (internal waste) and table 2 (external waste). A total of 2413.78t valve castings were produced throughout the year, with an internal waste rate of 1.15%, an external waste rate of 1.73% and a comprehensive waste rate of 2.88%.
Casting Defects | Air hole / slag hole | Shrinkage / porosity | Sand hole / sand inclusion | Crackle | Sticky sand | Deformation | Other |
Quantity | 8.7 | 0.81 | 4.97 | 6.17 | 1.95 | 0.56 | 5.67 |
Proportion | 31.26 | 2.91 | 17.86 | 22.17 | 7.01 | 2.01 | 16.78 |
Casting Defects | Stomata | Shrinkage cavity | Shrinkage porosity | Slag hole | Sand inclusion | Insufficient pouring | Eccentric | Other |
Quantity | 3.34 | 12.97 | 11.78 | 1.12 | 6.29 | 1.51 | 3.90 | 0.92 |
Proportion | 7.98 | 31.01 | 28.16 | 2.68 | 15.04 | 3.61 | 9.32 | 2.20 |
From the above statistics, it can be seen that the internal waste rate decreased by 2.39 percentage points, the external waste rate decreased by 2.85 percentage points and the comprehensive waste rate decreased by 5.24 percentage points before and after the improvement of valve castings. After taking improvement measures, the production of valve castings reduced waste, saved a total cost of 569200 yuan, and achieved good economic benefits.