The pass rate of die casting is a concept that applies to a system.
Die casting pass rate is a logical concept that can be calculated. The pass rate of the die casting machine side, the initial check of die casting, cleaning, post-treatment, machining, and transportation are all included in the composition of the pass rate of die casting, which is also known as the pass rate of the die casting process. According to general principles, the power train on the automatic transmission or clutch pass rate can do 95% is already at the top level (a well-known Japanese company's automatic transmission pass rate is 92%; in Europe, many enterprises use assembly line layout, some casting pass rate can do 97%), the general domestic factories in 80-90% or so, 85% pass rate should be in a profit balance point, and the power train on the automatic transmission or clutch pass rate can do 95% is already at the top level (a well-
What is the difference in pass rates between die castings with 95% and 99% success rates?
In the qualified rate of custom die casting, waste of die casting machine side material accounts for one of the largest proportions of scrap. It is also one of the most significant hidden costs in the cost of die casting. Given that it is part of the internal process, there is no issue with the next process being responsible for the next process, and because management personnel are more or less concerned with the pass rate of the machine, they will more or less ignore these points. In other words, many managers do not know where to begin from this point and do not know how to resolve the situation, so they choose to remain silent.
There are numerous objective issues that we must deal with, such as equipment issues, mold issues, spraying issues, and so on and so forth. These issues have a significant impact on the pass rate of die casting mold machines at the edge of the die. The failure of equipment and the mold will result in an increase in the number of cold mold parts produced. The inability of equipment and molds to function properly will result in an increase in the number of defective parts that are automatically identified. Mold thermal balance and spraying inconsistencies will both contribute to the appearance of die casting defects, indicating that this is a system-wide issue. Management and technology alone will not be enough to solve the die-casting system's problems.
What is the difference in pass rates between die castings with 95% and 99% success rates?
It represents a higher, more consistent standard of acceptance rate, as represented by the increase from 95% to 99%. The pass rate that we are going to talk about today is the pass rate of a machining operation. The pass rate, which is frequently mentioned in the die ring, is generally based on this information. Die casting defects are still blamed for the material waste that occurs during the machining of castings. Defects such as porosity, shrinkage cavity, leakage, inclusion, deformation, black skin, bruise, and so on are frequently found in this material. The most serious defect is the shrinkage cavity and leakage problem, which is also the most difficult to resolve and the most frequently occurring problem.
It is not difficult to achieve the 95% die-casting qualification rate as long as the die-casting company has fundamental management processes and standards in place, excellent tooling, an excellent die-casting process, and a continuous improvement team. In the actual manufacturing process, there are numerous instances in which the mold is sufficient under the premise of a qualified rate of 95% is more easily achieved.
The 99% pass rate, on the other hand, is an entirely different concept. Specifically, we're talking about a symbolic number that represents a higher and more consistent pass rate. It could be 97% or 99.7%, and the most important thing is to figure out how we can achieve excellence, and how we can do so in a stepwise manner.
As a result of the globalization of the economy, Chinese die casting companies do not lack for world-class equipment and tooling, nor do they lack for bosses and managers who have the vision and pattern of pursuing excellence. An organizational culture that promotes a holistic mindset, patience, and the ability to nurture an organization are what are lacking.
Five to ten years ago, we were unable to find our way due to a lack of objectives, but today the goals of the die casting industry are crystal clear: high stability, high yield, high efficiency, and low cost. These four points represent the objectives that die casting must achieve, and they can be paralleled but not reversed in any way. Because the organizational goal is distinct from the individual's goal, we are still perplexed about where we should go next. Even though the above four points represent the organizational objective, how many managers are familiar with the individual's objective as well as his or her own growth requirements?
What steps must be taken in order to achieve 99% of the qualified rate of die casting (the following contents are primarily concerned with shrinkage hole, leakage, and other issues)?
Create a project management team.
Senior management leads or collaborates with other members of senior management to form high-quality project teams. With a large number of managers who are too far away from the scene of the action, the field management of oh no expressed a clear point of view: "the tube is not good enough," because "near enough" is actually the process of working together.
Defining your objectives
A high target pass rate is an important prerequisite for successful casting, regardless of the difficulty of the casting. And everyone must recognize the importance of this goal. Our managers are frequently dissatisfied with the goals they have set for themselves. This is due to the fact that we do not have a core team within the organizational system, and building a core team will take time, effort, and planning on our part.
Objectives and responsibilities are broken down into smaller parts.
The decomposition of objectives and the division of responsibilities are particularly important. The majority of the issues that arise in the later stages are caused by a lack of thorough and thorough analysis in the early stages. The majority of ineffective enforcement is caused by ambiguous roles and responsibilities. Therefore, in accordance with the division of responsibilities, it is necessary to designate appropriate responsible persons. We'll need a group of people to talk about a fundamental understanding of responsibility, and only one person is ultimately responsible for everything that happens. In order to avoid the emergence of departmentalism and empiricism, it is necessary to appoint project management personnel with the appropriate qualifications to supervise.
