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Cost reduction for achieving competitiveness through industrial experimentation in SG casting for Automotive applicationRéduction des coûts pour atteindre la compétitivité grâce à l’expérimentation industrielle du coulage de graphite nodulaire (GN) pour l’application dans l’industrie de l’automobile

ABSTRACT Automotive OEMs face a tricky balancing act when dealing with their suppliers. At the same time, OEMs expect their suppliers to keep costs within reasonable limits. The biggest challenge in the global foundry industry is cost competitiveness without compromising on quality. The organisation had a significant challenge in meeting the customer’s cost expectations, and this exercise was taken up as a part of cost reduction. Conserving the scarce resource of Copper and maintaining the quality specification, thus demonstrating business intelligence, using the statistically evidenced innovative method, is the primary focus of this paper. The literature review has revealed that the approaches for achieving cost reduction are usually made by fault correction in casting, activity-based industry engineering, and waste reduction. Optimisation of the composition of alloys and deploying functional quality is the focus of this study. The Shainin approach and the regression model techniques were used to arrive at the optimum combination of the Mn and Cu % (Manganese and Copper). The scope is limited to as-cast grade pearlite+ ferritic SG Iron/Nodular Iron/Ductile Iron components and will not be inductively extendable to every component.