Abstract

In process control in the casting industry, the features of the product, such as diameter, thickness, density, are generally considered as quality characteristics and assignable causes affecting the process is tried to be determined by monitoring these quality characteristics in the quality control charts. However, instead of the features of the producing product as quality characteristics in the casting industry, the proportions of the elements that make up the product can also be accepted. Because the proportions of the elements that make up the product are desired to be within certain limits within the product and these generally vary. In addition, metal ratios, which can be selected as quality characteristics, can be monitored with quality control charts as in the properties of the product, but interpretation of out-of-control signals may not be sufficient. Therefore, in the solution of the problem, instead of quality control graphics, the process-oriented basis representations method in the literature can be used. As a result of the research in the literature, it has been determined that the process-oriented basis representations method has been used successfully in the modeling of geometric deviations in the manufacturing industry, but it is not applied in the process (chemistry, petro-chemistry, casting, etc.) industries, and in multivariate industrial production processes with interrelated quality characteristics. In this content, the aim of this study was is to show that metal alloy ratios can be used as quality characteristics and the process-oriented basis representations method can be applied in process control in the casting industry. The data used in the study were obtained from the production process of Brass Factory Directorate of Mechanical and Chemical Industry Company in Kırıkkale province between 01 January 2015 and 31 March 2015. The module in the Minitab package program was used to create the control charts. At the end of the study, it has been determined that in the process control in the casting industry, the element ratios that make up the product produced as quality characteristics can be selected and positive results can be obtained by monitoring the quality characteristics selected in this way with the process-oriented basis representations method. It is evaluated that the results obtained in the study will contribute both to the domestic and foreign literature theoretically and to the quality control applications in terms of practicality in the casting industry.

Keywords

• Casting
• Brass
• Process Oriented Basis Representation

Döküm Sanayinde Süreç Tabanlı Temel Gösterimleri İle İstatistiksel Süreç Kontrolü

Abstract

Döküm sanayinde süreç kontrolünde, kalite karakteristiği olarak genellikle üretilen ürünün çap, kalınlık, yoğunluk gibi özellikleri ele alınmaktadır. Söz konusu kalite karakteristikleri, genellikle kalite kontrol grafikleri ile izlenerek süreci etkileyen özel nedenlerin varlığı ortaya konulmaya çalışılmaktadır. Ancak döküm sanayinde kalite karakteristikleri olarak üretilen ürünün özellikleri yerine ürünü oluşturan elementlerin oranları da kabul edilebilmektedir. Çünkü ürünün içeriğini oluşturan elementlerin oranlarının, belirli sınırlar arasında olması istenmekte ve genellikle değişkenlik göstermektedir. Kalite karakteristikleri olarak seçilebilen metal oranları, ürünün özelliklerinde olduğu gibi kalite kontrol grafikleri ile izlenebilmekte ancak kontrol dışı sinyallerin yorumlanması yeterince yapılamamaktadır. Dolayısıyla sorunun çözümünde kalite kontrol grafiklerinin yerine literatürde yer alan süreç tabanlı temel gösterimleri metodu kullanılabilir. Yapılan literatür araştırması neticesinde, süreç tabanlı temel gösterimleri metodunun, imalat sanayinde geometrik sapmaların modellenmesinde başarılı bir şekilde kullanıldığı ancak proses (kimya, petro-kimya, döküm vb.) endüstrilerinde ve birbiriyle ilişki içinde olan kalite karakteristiklerin bulunduğu çok değişkenli endüstriyel üretim süreçlerinde uygulamasının olmadığı tespit edilmiştir. Bu kapsamda yapılan bu çalışmanın amacı, döküm sanayinde süreç kontrolünde, metal alaşım oranlarının kalite karakteristiği olarak kullanılabileceğini ve yine süreç tabanlı temel gösterimleri metodunun uygulanabileceğini göstermektir. Çalışmada kullanılan veriler, 01 Ocak 2015-31 Mart 2015 tarihleri arasında Kırıkkale ilinde yerleşik Makine ve Kimya Endüstrisi Kurumu’na bağlı Pirinç Fabrikası Müdürlüğünün üretim biriminden elde edilmiştir. Kontrol grafiklerinin oluşturulmasında MINITAB paket programında yer alan modül kullanılmıştır. Çalışmanın sonunda; döküm sanayinde uygulanan süreç kontrolünde, kalite karakteristiği olarak üretilen ürünü oluşturan element oranlarının da seçilebileceği ve bu şekilde seçilen kalite karakteristiklerin süreç tabanlı temel gösterimleri yöntemi ile izlenerek olumlu sonuçlar elde edilebileceği tespit edilmiştir. Çalışmada elde edilen bulgu ve sonuçların gerek ulusal gerekse uluslararası literatüre hem teorik ve hem de pratik katkı sağlayacağı düşünülmektedir.

Keywords

• Döküm
• Pirinç
• Süreç Tabanlı Temel Gösterimleri

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