Optimization of process factors for controlling defects due to melt shop using Taguchi method

Sushil Kumar (Mechanical Engineering Department, Indo‐Global College of Engineering, Abhipur, India)
P.S. Satsangi (Mechanical Engineering Department, PEC University of Technology, Chandigarh, India)
D.R. Prajapati (Mechanical Engineering Department, PEC University of Technology, Chandigarh, India)

International Journal of Quality & Reliability Management

ISSN: 0265-671X

Publication date: 4 January 2013



The purpose of this paper is to identify the influencing factors which cause casting defects and determination of optimum value of factors to minimize these defects in a melt shop industry, situated in north India. Percentage contribution of these factors is also estimated to develop an empirical expression between process performance and independent input variables.


Optimization technique for melt shop process parameters of a cast iron differential housing cover based on the Taguchi method is proposed. The focus of this paper is on the robustness of the sand casting process and the case study is based upon a leading automobile foundry industry, located in north India. Taguchi's experimental design and regression analysis techniques are used to optimize the control factors, resulting in improvement of the product quality and stability. The various confirmation tests are also carried out in the range of process parameters.


The outcome of this case study is to optimize the process parameters of the melt shop process, which leads to minimizing the casting defects. The process parameters considered are: mild steel, pig iron, cast iron, ferrosilicon, lime stone, ferromanganese, cock and ferrochrome. Best proportions of charge constituents that are contributing to casting defects in melt shop are identified in the first stage. These identified factors are analyzed using “Design of Experiments” approach in the second stage. ANOVA analysis is also performed for robust design of factor values and an appropriate empirical model is formulated.

Research limitations/implications

A lot of effort has been put into developing the appropriate empirical model for the automobile foundry industry but additional work may also be done for gating design of the casting industry.

Practical implications

The paper shows that the process parameters of any casting industry can be optimized and casting defects in the melt shop can be identified in the first stage.


The research findings could be applied to various manufacturing industries, especially the casting industries.



Kumar, S., Satsangi, P. and Prajapati, D. (2013), "Optimization of process factors for controlling defects due to melt shop using Taguchi method", International Journal of Quality & Reliability Management, Vol. 30 No. 1, pp. 4-22. https://doi.org/10.1108/02656711311288397

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