提高出品率与降低废品率.docxVIP

YIELD IMPROVEMENTS VERSUS SCRAP RATE REDUCTIONConventional attempts at reducing costs are often focused on scrap reduction. Yield is often indicated as the ratio of the casting weight to the total pour weight. In a hypothetical case, let us consider a casting that has yield of 48%. If the current scrap level associated with the casting is around 5%, the effective yield is around 45.6 % (48% *(100-5/100) =45.6%). Let us assume that the yield of that specific casting is increased (by the principles outlined in this paper) to 73% and there is an associated scrap equal to 10%. The resultant effective yield (considering loss due to scrap) is around 65.7% (73% *(100-10/100)= 65.7%). Thus, the overall effect of yield improvement can be a more significant cost reduction tool in spite of an increase in scrap levels. The authors do not minimize the importance of quality improvements and scrap reductions. Scrap reduction through process control and continuous improvement is essential for the survival for most foundries. It is merely suggested that yield improvement should also be given due consideration. Metal weight to mold ratio is often considered important since it indicates the volume utilization of the mold for a given casting. The increased volumes of cores used in a mold also lead to increased costs. All yield improvement efforts should include ways to get additional castings per mold and minimize the volume of cores used in each mold. TEN PRINCIPLES TO ACHIEVE HIGH YIELDThe following ten rules or ideas assist in reducing the gating system dimensions and volume and result in higher yields without compromising casting quality. Two case studies at the end of the paper illustrate applications of these principles. 1) Use of Ceramic Foam FiltersConventional application of filters is based on reducing the incidence of scrap related to inclusions. However, the proper use of ceramic foam filters in the runner system can help reduce the length of the runner and gates [1]. Fl