Time Reduction and Quality Improvement of Galvanizing Process of Power Structures

Abstract

Most manufacturing organizations face the critical problems that the existing production rate cannot meet the customer demand and the lead time is not satisfactory to the customer. This work is focused on improving production rate as well as quality improvement for galvanizing which is one key component for many industries. Problems have been identified by visual inspection and recorded monitoring that the quality defects due to uneven dipping time taken in the galvanizing bath and low quality of concentration in the process tanks. Research paper related to quality measures during production of galvanized products is considered for quality implementation of galvanizing plants. Material quality rejection through the quality department is considered and company’s old data sheet having monthly production, monthly material rejection is studied and observed. Also, the process tank record data sheet has been taken into consideration. Thus daily concentration of the process tank is recorded and is collected. The timely filtering and maintaining the standard concentration quality of the process tank is carried out to decrease the number of defects observed in the galvanizing process. The standard dipping time of the material is also been decided and is followed throughout the production. There is 5% decrement in material defect (rejection rate) and 7% increment in the production rate.