The Research Of Die Casting Product For Process Optimization And Quality Improvement

This article is based on lean production-related theory, conducted adetailed reason analysis of die casting firm F company’s main die castingproduct—Hydraulic Tensioner Body on time delivery issues. And took Atype body as an example, based on the background of mass production, byusing method of value stream map, through data collection and observation,identify capacity bottlenecks of processes as well as facility layout, handling,waiting, inadequate equipment and other factors, distinguished between thevalue-added and non-value-added link in the process. Subsequently, inaccordance with the principles of lean, re-planned capacity planning, adjustedthe product line layout, enhanced the bottleneck process capacity by addingmachining transfer, combined with the product cell to eliminate wasted points,and drawn a future state value stream map.The first two chapters introduce the company background and tensionerbody’s function, product characteristics, production process flow, as well as the cost structure of the product. Chapter III, focusing on reason analysis ofthe tensioner body on time delivery issue, including production and processanalysis, machine efficiency, quality variation, and so on. The fourthChapter， discusses about capacity improvement and balanced production, aswell as process optimization implementation. Focus on improving thebottleneck capacity, work in process inventory backlog, labor costs, optimizefacility layout. The fifth Chapter works on quality optimization, statisticalanalysis, experimental of design （DOE） to improve yield and reducequality cost and ensure successful implementation of lean improvements.