SUNConferences, Southern African Institute of Industrial Engineering 2013

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Investigating the Impact of Poor Utilisation of Quality Management System in a South African Foundry
Zanele Promise Mpanza, Didier Nyembwe, Hannelie Nel

Last modified: 2013-06-18


Background: In 2007 alone, twenty six foundries were closed down when the castings directory industries was released. A high scrap rate due to a lack of quality management is one of the root causes of low productivity and low profits, resulting in closures. Method: This research paper focusses on the impact of defects on productivity and monetary losses due to a lack of quality management in sand casting. Data was gathered on defects, monetary losses due to scrap, and productivity over a period of six months at McWade Productions. The standard multiple regression analysis method was used to assess the ability of five defects (Cross jointed, Bad mould, Shrinkage, Corefault, and Gas porosity) to predict monetary and productivity losses. Results: Cross jointed and Bad mould defects had a correlation coefficient of 0.727 and 0.716 respectively which indicated a strong positive correlation. The overall variance explained by the model was 61%, F = 16.263, p<.005. Thus the prevalence of these two types of defects can significantly predict monetary and productivity losses. Conclusion: Foundries should concentrate on eliminating Cross jointed and Bad mould defects to avoid a high scrap rate and improve productivity.


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