Quality engineering, which is a universal technology for applying descriptive statistics and related methods to develop new technologies and product development processes, was registered as ISO16336 in 2014, providing guidelines for applying effective optimization methods for achieving robust products. It is applicable to many areas such as machines, chemical products, electronics, foods, consumer goods, software, new materials, and services, and excellent results have been reported in many papers. However, in the casting field, very few reports have been published in Japan. This work reviews parameter designs related to downloadable reports from all over the world in the hope that it will contribute to casting engineers requiring specific examples for studying methodologies.

  Nowadays, numerical simulation of casting processes is widely used to optimize casting designs and conditions at various casting companies. However, it is impossible to control all the process parameters strictly, resulting in casting defects in some cases because the casting conditions are not those chosen by simulation. This paper proposes the Taguchi method based on solidification simulation as a method for selecting robust designs according to the manufacturing scene and confirms the effectiveness of the method.

  This report describes the application of quality engineering for reducing inconsistencies of system sand to attempt the use of data-driven approach (decision-making using data). The influx of core sand was assumed to be one of the factors causing inconsistencies of system sand, and this was set as the noise factor. In addition, the bentonite amount, bentonite type (blended rate), kneading time, coal powder, starch, and wetting agent were selected as control factors to conduct direct product experiments. Experimental results confirmed that bentonite amount, bentonite type, coal powder, and wetting agent are effective for reducing the inconsistencies. Most of these factors are current levels, and the only realistic and modifiable factor was change in bentonite type.

  These results indicate that change of bentonite type has little effects for reducing inconsistencies, but conversely, it means that factors for reducing costs without affecting inconsistencies can be determined with this approach.

This theme was conducted in 2009 and reported at the Kansai Branch meeting of Japan Foundry Engineering Society in 2010. The approach has been improved through subsequent efforts and experience, and these shall be reported in the following as well.