Product category:
Casting and Forging Subcontracting Services
News Release from: Doncasters Group | Subject: Lean manufacturing
Edited by the Manufacturingtalk Editorial
Team on 21 December 2007
Lean manufacturing boosts turbocharger
output
A manufacturer of turbocharger wheels reports that lean manufacturing initiatives have improved efficiency and working conditions as well as the business' environmental footprint.
Manufacturer of turbocharger wheels for the automotive and power generation industries, Doncasters Trucast, reports that a number of Lean manufacturing projects based on the Kaizen principle of continuous improvement have improved efficiency and working conditions as well as the business' environmental footprint Trucast, based in the UK's Isle of Wight, is part of the global engineering firm, Doncasters Group, which has focused on improving efficiency through a company-wide adoption of lean manufacturing techniques
This article was originally published on Manufacturingtalk on 5 May 2003 at 8.00am (UK)
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One of the main pillars of the introduction of Lean Manufacturing at Doncasters Precision Castings - Deritend - is Continuous Improvement - Kaizen.
Lean manufacturing with six sigma and Kaiken
A series of lean manufacturing projects resulted in financial savings of more than GBP200,000 in a year for Ross and Catherall following adoption of the Doncasters' Lean Sigma Charter.
The Trucast site is a particularly successful example of this policy with significant improvements to the performance of both employees and the use of materials in the manufacturing process.
These improvements will help to slow the rise of production costs in the future.
A recent project that illustrates the success of the commitment to lean manufacturing is the initiative to combine the wax injection and pattern cleaning operations in the wax department.
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* Reorganisation - reorganisation of the department was needed to improve the workspace for employees, improve operational efficiency and accommodate business growth.
Following a Kaizen event, a new layout was designed and a new wax room constructed.
New working practices, job roles and targets were also developed and regularly reviewed with staff through continuous training sessions and presentations.
The changes have resulted in significant improvements to the process, including th following.
* Reduction in work-in-progress (production inventory) and lead time has led to improved data accuracy and 'on time delivery' to satisfy customer demand.
* New layout resulting in improved product flow and the opportunity for capacity expansion.
This also enabled Trucast to create an amenities room and dedicated on-line material store to address health and safety issues.
* Improved working environment resulting in operator job satisfaction and improved customer perception.
Trucast has also improved its green credentials with the help of another Kaizen initiative, this time to improve the level of gas consumption in the casting lines.
Wasteful working practices were identified within the casting operation using a structured Lean Sigma approach.
Gas consumption on the casting lines was measured, using sub-metering, and the data was analysed to identify opportunities.
Trucast told manufacturingtalk.com that trials were also carried out to improve the utilisation of gas fired furnaces, with the results being used to develop new working practices that outline shut-down procedures between shifts.
Daily monitoring is in place to ensure the targets are achieved.
Eric J Lewis, chief executive of Doncasters Group, said: "A continuous improvement culture is essential in today's manufacturing climate.
UK manufacturers must build their entire business model around lean operating effectiveness and a cradle to grave approach covering all functions, from new product introduction, supply chain and manufacturing through to administration and distribution".
He continued: "At Doncasters, we never take success for granted and are continually searching for better ways to deliver results for our customers.
The series of lean manufacturing projects at our Trucast business just goes to show what can be achieved by a commitment to lean principles".
* About Doncasters - the Doncasters Group is a fast growing leading international manufacturer of performance and tolerance critical engineering components for a variety of end market applications.
Doncasters excels in working with alloys and metals that are difficult to shape and form, and that are required to operate in demanding ambient conditions.
The company's unparalleled range of products and processes has been developed to offer customers a broad, vertically integrated capability.
Core manufacturing processes include precision casting, forging, fabrication, machining and production of superalloys.
Key products include the following.
* Turbine airfoils, rings and casings.
* Structural castings.
* Compressor airfoils.
* Combustion components and fabrications and exhausts for application in gas turbine engines, aerostructures.
* Components for airframe applications.
* Compressor and turbine wheels for the speciality turbocharger market.
* Ranges of fastenings for construction, industrial, truck, recreational and military markets.
The company offers well-developed supply chain integration solutions, delivering complex assemblies and engine-ready components to its customers.
Doncasters employs some 7,100 people across U.S.A., Europe, China and Mexico.
The Group has institutionalised Lean manufacturing and Six Sigma principles throughout its operations.
Doncasters recently announced that it had completed the acquisition of FastenTech Incorporated, a leading manufacturer of precision components and fastenings, from CVC Capital Partners for US$492 million.
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