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Improving Production Efficiency of Large Size Molds as a Result of Innovative Quality Control Process

Treść / Zawartość
Identyfikatory
Warianty tytułu
Języki publikacji
EN
Abstrakty
EN
One of the basic elements of the technological chain of manufacturing products in the European Union is the metal processing sector, which is one of the dynamically developing industries. An important department in the aforementioned sector is the production of unconventional, large-size injection molds and tools weighing more than 10 tons. Very often large-size components in the production process must be precisely checked and subjected to appropriate corrective actions at the quality control stage, in order to avoid non-compliance with customer requirements, and thus increased costs related to reducing production efficiency, logistics of large-size elements from the customer back to the manufacturer of the mold in order to correct it, and also complaints of the final product connected with dimensional changes and surface defects in the casting process. This paper presents a case study of the implementation of the innovative quality control process to verify the production of large-size molds for aluminum high pressure casting with the spotting press machine, allowing for product quality improvement. The introduction of the innovative press for spotting molds to the quality control stage also leads to the improvement of production efficiency, which was confirmed by the results of an increase of the OEE coefficient in the entire production process. In addition, a significant reduction in the production time of products was achieved, and the cost of the mold production process was lowered.
Rocznik
Strony
457--465
Opis fizyczny
Bibliogr. 25 poz., fig.
Twórcy
  • Czestochowa University of Technology, Poland
autor
  • Czestochowa University of Technology, Poland
autor
  • Czestochowa University of Technology, Poland
autor
  • Technical University Zvolen, Slovak Republic
autor
  • Technical University Kosice, Slovak Republic
Bibliografia
  • 1. Concer, D. and Marcondes, P. V. P. (2017). Experimental and numerical simulation study of porosity on high-pressure aluminum die casting process. Journal of the Brazilian Society of Mechanical Sciences and Engineering Vol.: 39 Issue: 8 pp. 3079-3088.
  • 2. Großmann, K. and Wiemer, H. (2005). Simulation of the Process Influencing Behaviour of Forming Machines. Steel Research International 76, No 2/3, Stahleisen GmbH Düsseldorf.
  • 3. Haddag B., Nouari, M. and Moufki, A. (2016). Some cases of machining large-scale parts: characterization and modelling of heavy turning, deep drilling and broaching. AIP Conference Proc. 1716, pp. 1-9.
  • 4. Hamrol, A. and Mantura, W. (2005). Quality Management. Theory and Practice, Warsaw: PWN Editors.
  • 5. Hashikawa, Ryuichi & Osada, Toshiko & KUDO, Kentaro & Tsumori, Fujio & MIURA, Hideshi (2016). Control the Distortion of the Large and Complex Shaped Parts by the Metal Injection Molding Process. Journal of the Japan Society of Powder and Powder Metallurgy, Vol. 63. pp. 473-478.
  • 6. Jurgen, S. and Uwe S. (1994). Finishing of dies and moulds An approach to quality‐orientated automation with the help of industrial robots. Industrial Robot: An International Journal, Vol. 21 Issue: 1, pp.28-31.
  • 7. Nowicka-Skowron, M. and Ulewicz, R. (2015). Quality management in logistics processes in metal branch. In: METAL 2015 – 24th International Conference on Metallurgy and Materials, Conference Proceedings. pp. 1707–1712.
  • 8. Nunes, V., Silva, F. J. G., Andrade, M. P. et al. (2017). Increasing the lifespan of high-pressure die cast molds subjected to severe wear. Surface & Coatings Technology Vol. 332, pp. 319-331.
  • 9. Lynch, P., Walsh, M. and Harrington, D. (2010). Defining and Dimensionalizing Organizational Innovativeness. International CHRIE Conference-Refereed Track, USA.
  • 10. Łuszczak, M. and Dańko, R. (2013). Stan zagadnienia w zakresie odlewania dużych odlewów strukturalnych ze stopów aluminium. Archives of Foundry Engineering, Vol. 13, Nr 3, 113-116.
  • 11. Milutensil Company (2015). Lower mold-testing costs with spotting press, Moldmaker.
  • 12. Skrzypek, K. and Dąbrowski, K. (2017). Using of integrated systems in Polish manufacturing enterprises from metal and automotive industry. Zarządzanie Przedsiębiorstwem, Zeszyt 2, p. 22 (in Polish).
  • 13. Oechsner, R., Pfeffer, M., Pfitzner, L., Binder, H., Muller, E. and Vonderstrass T.(2003), From overall equipment efficiency (OEE) to overall Fab effectiveness (OFE). Materials Science in Semiconductor Processing 5.
  • 14. Onozuka, H., Utsumi. K., Kato. T., Takahashi. H. and Obikawa. T. (2013). Optimal design of a damped arbor for heavy duty machining of giant parts. Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol. 7, pp. 171-186.
  • 15. Sarmiento-Merida, L. A., Guevara-Morales, A. and Figueroa-Lopez, U. (2018). Determining the Optimum Parting Direction in Plastic Injection Molds Based on Minimizing Rough Machining Time during Mold Manufacturing. Advances in Polymer Technology, Vol. 37 Issue: 1.
  • 16. Schöne, Christine & Stelzer, Ralph & Schmidt, Ulf & Süße, Dietmar (2010). Reverse Engineering for Spotting of Sheet Metal Forming Parts.
  • 17. Flavio M. and Josh, K. (2015). The Hidden Value of a Spotting Press As mold complexity increases, so, too, does the complexity of maintenance, which advances the role of spotting in mold validation.
  • 18. Shimizu, T., Kitazima, A., Nose, M., Fuchizawa, S. and Sano, T. (2001). Production of large size parts by MIM process. Journal of Materials Processing Technology, 119 (1-3), pp. 199-202.
  • 19. Skotnicka-Zasadzien, B., Wolniak, R. and Zasadzien, M. (2017). Use of quality engineering tools and methods for the analysis of production processes – case study. Proceedings of the 2nd International Conference on Economic and Business Management Book Series: AEBMR Advances in Economics Business and Management Research Vol. 33, pp. 240-245.
  • 20. Stabryła, A. (2005). Categorization as an Instrument in Managing Company Development Capacity. Argumenta Oeconomica Cracoviensia, No 3.
  • 21. The "invisible" sector of European industry - now in the center of attention. Metalworking and production of metal products, European Commission, 2010 (in Polish).
  • 22. Walkington, W.G. (1997). “Die Casting Defects. Causes and solutions”. North American, Die Casting Association, Illinois U.S.A.
  • 23. Stasiak-Betlejewska, R., Ulewicz, R., (2016). The effectiveness of selected machinery and equipment in the woodworking joinery, in: The Path Forward for Wood Products: A Global Perspective – Proceedings of Scientific Papers. pp. 149-156.
  • 24. Zasadzien M., Midor K (2015), Innovative Application of Quality Management Tools in a Hard Coal Mine, Science And Technologies in Geology, Exploration And Mining, Vol. III, pp. 415-422.
  • 25. Zorawski, W., Chatys, R. Radek, N. et al. (2008), Plasma-sprayed composite coatings with reduced friction coefficient. Surface & Coatings Technology Vol. 202 Issue: 18, pp. 4578-4582.
Uwagi
Opracowanie rekordu ze środków MNiSW, umowa Nr 461252 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2021).
Typ dokumentu
Bibliografia
Identyfikator YADDA
bwmeta1.element.baztech-9dc31754-b181-454f-8c05-171862e982d8
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