Imagine this: 7 out of 10 castings from your production line are rejected
That was the crisis one of our clients faced in centrifugal casting. Porosity issues had pushed rejection rates to a staggering 70–80%, causing not only financial strain but also disruption to delivery commitments. Despite trying multiple fixes, improvements were modest and unsustainable.
Project Overview
The Challenge
At Swanhans, we knew the answer wasn’t a quick patch — it required a systematic, scientific approach.
We began with a Cause-and-Effect analysis to map out every possible contributor to the defect. Using WHY-WHY analysis and an in-depth literature review of centrifugal casting physics, we identified 10–12 potential factors at play.
Instead of treating them all at once, we tested each factor scientifically. This disciplined process led us to the prime root cause: inefficient heat rejection through the mold.
Two parameters were driving it:
- Molten temperature of the metal
- Mold material properties
With this insight, we applied the Theory of Constraints and Design of Experiments (DOE) to fine-tune mold design and optimize temperature ranges.
Our Solution
The outcome? A dramatic drop in rejection rates, higher yield, and renewed confidence in production quality.
This project reinforced a simple truth: lasting solutions don’t come from shortcuts — they come from structured problem-solving, persistence, and deep technical understanding.
👉 If you’ve faced stubborn quality issues, what’s been your biggest learning in uncovering the real root cause?
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