Waste Minimization and Cost Reduction in Process Industries

Investment casting, also known as lost wax precision casting process is the technology used to produce a casting products which have complex geometry shapes, surface smoothness, shape and dimensional precision, thus the resulting products performs high quality and added value. Impeller could be considered as one of the example of the investment casting product. In Indonesia, the investment casting technology has not yet been widely applied. Only few industries use this technology. The manufacturing technology, machineries and materials are still imported. By analyzing the required process and materials, which is then followed by some trials and analysis, this study provides an alternative use of local materials and simple technology to produce good quality products. This can subsequently be applied in small-medium scale industries and in educational institute. The research has resulted a formula of modeling wax, slury and the processing techniques. The experiments performed in this research to produce the impeller used steel (DIN standard GS30Mn5) as the main material.

Hungarian Journal of Industrial Chemistry, 2011

In the forging industry typical in the 21st century, economical production requires environment-friendly manufacturing of integrated and complicated products of larger and larger masses. Difficulties to be solved require effective researches, technological developments and cost analyses. Most frequently, cost analyses call the attention to energy demand of forging, to tool costs and to the efficiency of raw material usage. Preservation and enhancement of competitiveness based on environment-friendly technological solutions are one of the most important challenges for the forging industry in the 21st century. Our case study presents BY (The Best Yield) treatment technology of a planetary carrier developed in the RABA forging plant. Development of the basic technology required integrated application of CAD (Computer Aided Design) – CAE (Computer Aided Engineering) and a test method using thermographic camera. Integration of IT (Information Technology) systems created a new design meth...

Engineering and Technology Journal

Solid Waste Management (SWM) is a term used to determine greatest energy-efficient and least-polluting ways to deal with the different components and items of community's Solid Waste stream. The solid waste could be either in solid or liquid form. Solid waste could be defined as, "Any material that is not required by the owner, fabricator or processor." Solid Waste could be classified as Domestic waste, Industrial waste, Waste from oil plant, Electronic-waste, Construction waste, Agricultural waste, Food treating waste, Bio-medical waste, and Nuclear waste. Due to social and environmental significances, waste reduces, reuse, and recycle have become necessities in minimizing the environmental damage that could happen through waste disposal. Steel products may be used in various construction and industrial applications, such as machines, bridges, buildings, vessels, highways, machinery, tools, and automobiles. It is estimated that the world's annual production of Steel is 1500 Million tons and that 85% of annual steel production is recycled worldwide. In this research, a framework for steel fabrication waste management is suggested consists of three stages; these stages are scrap classification stage, reusable scrap stage, and non-reusable scrap stage. The framework is applied in one of the Iraqi Ministry of Oil Companies; the Heavy Engineering Equipment Company, which is an important industrial company specialized in steel fabrication and construction work.

2023

A short brief about Integrated Iron & Steel Production

International Journal of Productivity and Quality Management, 2022

Total Productive Maintenance (TPM) is a lean manufacturing technique that concentrates on improving the overall equipment effectiveness of a machine which is used for production. TPM ensures the availability of a machine and its implementation method involves continuous improvements which lead to reduced losses. This paper presents a case study on improving Overall Equipment Effectiveness (OEE) of equipment in a manufacturing company which manufactures steering housing and also to determine and address the facets which act as barriers in implementing TPM in the machine shop. The major issues faced by this company are the lack of stock in feed and tool changeover time which reduces the availability of the machine which in turn results in tremendous drop in OEE. The current level of OEE for that particular machine is found to be 54.09%. By implementing Lean concepts such as TPM and Single Minute Exchange of Dies (SMED) would improve OEE by 6.06%.

TJPRC, 2014

Cleaner production is a idea which applying on products, manufacturing process and pollution prevention for economic and environmental sustainable development. How to implement cleaner production in Indian foundry industry is the main issue in the field of sustainable development of economy. Waste has to be regenerated and used again as a material to the maximum possible extent. Waste is becoming an increasingly traded product, where excellent profits can be made.devlopment of the foundry with new technology of cleaner production, namely: improving housekeeping, improve raw materials, increasing the metal yield, improve the efficiency energy use, reduce foundry by-products and improved production planning. This paper purpose is to suggest modal for each foundry department(if required) which implement different cleaner production technologies to improve environmental and economic benefits.

Social Science Research Network, 2015

The paper gives an account of the control of technological parameters in the manufacturing areas of rolling, forging and extrusion, besides the analysis of their role-playing to yield a fit component of right and requisite mechanical properties. The control of process parameters, the various dependent and independent variables, with efficient and frequent monitoring of recommended/design process parameters is vital towards controlling the manufacturing and hence economy of the manufacturing process. It is necessary to have a holistic approach to control of process in terms of not only the desired geometry and metallurgy or consequent service behaviour, but also the socio-technological impacts of the process; viz which technology is better suited in long term interests of the society, vis-à-vis the assured supply of raw materials or energy resources, and containment of costs within the complex global economic pressures. High temperature metallurgical operations also render the manufacturing process to difficulties of environmental degradation necessitating numerous end of pipe recommendations. This calls for a usual PDCA (Plan, Do Check Act) approach as commonly applied by industries implementing quality management system (QMS) today; though at times that should have concentrated more for engineering clues. Thus optimization of given process for a balance of hot or cold working may be driven in near future by more of techno commercial reasons, given the increasing employment of non-conventional technologies of powder metallurgical (P/M) forging, or like of swarf forming. The advantages here accrue because of shorter process cycle in former and resource recycling and conservation in latter. As a prelude to environmental upgradation, new re-engineering and redesigning imperatives may be necessitated to fulfill the goals of competitive manufacturing in metal forming.

TJPRC, 2013

Lean manufacturing is a technique employed to increase the value of a product by eliminating wastes and lead time. Now a day’s most of the waste generating in the steel plant is in the form of rework which lean considers it as its wastes. In this paper authors tried to identify the wastes occurring in the various departments of the steel plants and then analyzed the causes and sub-causes of the wastes with the help of fishbone diagram, and the suitable remedies are being provided.

Journal of Applied and Advanced Research, 2017

Production of steel in steel Industry is accomplice for the generation of solid waste materials like sludge, slag, dust etc. In recent days most part of wastes are generated from steelmaking process which is a focus point now-a-days. The solid waste generation, presently in Indian steel industry is in the range of 400-500 kg/t of crude steel and recycling rate varies between 40-70 % which lead to higher production costs, lower productivity and further environmental degradation. It is very essential not only for recycling of the waste valuable metals and mineral resources but also to protect the environment. I Solid waste management in steel industry is broadly classified in "4 R" i.e. reduce, reuse, recycle and restore the materials. The aim of the paper is to explore the various developments for total recycling of solid waste generated from steel industry, so that the vision for making "clean & green steel with zero waste" can be achieved for survival and growth of steel business in future.