Potential Applications of 7Epsilon

 

Sample Foundry Case Studies

 

  • The 7Epsilon concept has been developed for the benefit of foundry industry. It can be used for investment casting, sand casting, steel making, pressure die casting, gravity die casting processes etc. including all of its sub processes like mould/core making, melting, casting, shell making, heat treatment and machining process etc. It is equally applicable to other manufacturing processes such as powder compaction or biotechnology.
  • It is designed to benefit process engineers and quality managers who are responsible for the successful operation of one of the casting processes including its sub-processes in ISO 9001:2008 certified foundries or foundries who wish to acquire ISO9001:2015 or AS9100:2016 certification.
  • It is a tool that can be used during process FMEA for rootcause reasoning - to identify and carry out corrective actions.
  • It is applicable even if the current rejection rate is 1-2%. The unique penalty matrix will help you to identify trends in factor settings by designing a penalty function to lower your rejection rate further by determining how many times you had zero percent rejection rate and 1 – 2% rejection rate over the last six months or for the last 30 or 50 batches.
  • It is also applicable during design and development stages of new cast components or in-process quality improvement studies undertaken at the production stage.
    • In-process quality improvement phase
      • The in-process data available in this phase is unstructured and may be scattered over number of data bases. The data is normally linked via date and time of manufacture along with a corresponding batch/heat number or a unique identifier. p-matrix team can help you to link the heterogeneous data bases in an automated way.
      • Penalty matrix based data visualization technique will help you to discover interactions and optimal regions in factor settings easily.
      • It also enables you to extract process knowledge (or actionable information) from data so that it can be reused later.
      • The product specific process knowledge or the organisational knowledge is reused to interpret correlations discovered by penalty matrices.
    • Product development and initial process specification phase
      • The data available in this phase normally consists of number of design of experiments, initial production runs on prototypes and parametric studies undertaken on casting process simulation software.
      • Penalty matrix based data visualization technique will help you to discover interactions and optimal regions in factor settings easily.
      • It also enables you to extract process knowledge (or actionable information) from data so that it can be reused later.
      • The product specific process knowledge or the organisational knowledge is reused to interpret correlations discovered by penalty matrices.
  • In a jobbing environment, where you may not repeat the same job again, jobs/products that share similar production settings can be combined together to develop a ‘family of products’. Data can be grouped for a ‘family of products’ and analysed together.