Focusing core binder needs.Inside This Story * Design for Six Sigma The introduction to this article provides insufficient context for those unfamiliar with the subject matter. Please help [ improve the introduction] to meet Wikipedia's layout standards. You can discuss the issue on the talk page. translates customer requirements into meaningful, verifiable coremaking design characteristics. * Coremaking parameters that maximize In a graphical environment, to enlarge a window to the full size of the screen. See Win Maximize windows. casting characteristics are identified to achieve a more robust design. * Experiments designed on the basis of those characteristics determined that binder binder: see combine. An earlier Microsoft Office workbook file that let users combine related documents from different Office applications. The documents could be viewed, saved, opened, e-mailed and printed as a group. level had the greatest effect on the greatest number of properties. Those familiar with phenolic phe·no·lic adj. Of, relating to, containing, or derived from phenol. n. Any of various synthetic thermosetting resins, obtained by the reaction of phenols with simple aldehydes and used as adhesives. urethane urethane (yoor´ithān´), n ethyl carbamate used as an anesthetic agent for laboratory animals, formerly used as a hypnotic in humans. coldbox (PUCB) binders are well aware of the sheer Sheer and similar can mean:
The purpose of this article is to help metalcasters identify the right binder product for a given metalcasting application while maximizing max·i·mize tr.v. max·i·mized, max·i·miz·ing, max·i·miz·es 1. To increase or make as great as possible: data value and minimizing subjective subjective /sub·jec·tive/ (sub-jek´tiv) pertaining to or perceived only by the affected individual; not perceptible to the senses of another person. sub·jec·tive adj. 1. data interpretation using the Design for Six Sigma (DFSS DFSS Design For Six Sigma DFSS Defence Force School of Signals (Australian Defence Force) DFSS Decision Frontier Solutions Suite (Informix) DFSS Dielectric Frequency Selective Surface ) concept. Defining and Measuring One of the most important elements in DFSS is to clearly understand the needs of file metalcaster (and the end-user (job) end-user - The person who uses a computer application, as opposed to those who developed or support it. The end-user may or may not know anything about computers, how they work, or what to do if something goes wrong. ) and the level of importance assigned as·sign tr.v. as·signed, as·sign·ing, as·signs 1. To set apart for a particular purpose; designate: assigned a day for the inspection. 2. to each need. This process is known as determining the "voice of the customer." There are maw ways of deciphering the voice of the customer, such as market research, surveys, customer meetings and operation audits. A well executed executed 1) adj. to have been completed. (Example: "it is an executed contract") 2) v. to have completed or fully performed. (Example: "he executed all the promises made in the contract") 3) v. voice of the customer investigation gives fundamental insights into the customer's operations and needs, which, if met, lead to products and services that provide superior value and customer satisfaction. When we apply the voice of the customer process to metalcasting facilities and their expectations for sand binders, a number of factors need to be considered. 1. Defining the properties of the sand core or mold mold, name for certain multicellular organisms of the various classes of the kingdom Fungi, characteristically having bodies composed of a cottony mycelium. The colors of molds are caused by the spores, which are borne on the mycelium. that result in a good and profitable casting often is difficult. 2. Good aesthetics aesthetics (ĕsthĕt`ĭks), the branch of philosophy that is concerned with the nature of art and the criteria of artistic judgment. in sand cores and molds are no guarantee of casting quality. 3. The definition and measurement of what makes a good core is non-standardized and subject to opinion. 4. The properties of the PUCB binder required to make a good core and improve it are similarly subjective. 5. The interaction of PUCB binder's core production properties vs. core quality properties are complex. 6. Other variables in the core manufacturing process can interact Interact can refer to:
Fall of Interact While the Game Boy device was first released, Interact acquired the rights to sell Datel's Action Replay with the PUCB binder's properties and affect the core and casting quality. Voice of the customer is a process that aims to remove the ambiguity Ambiguity Delphic oracle ultimate authority in ancient Greece; often speaks in ambiguous terms. [Gk. Hist.: Leach, 305] Iseult’s vow pledge to husband has double meaning. [Arth. of subjective customer requirements and determine objective operation requirements. The metalcaster is concerned with reducing casting defects, finishing costs, core machine and tooling downtime The time during which a computer is not functioning due to hardware, operating system or application program failure. , raw material and process cost of cores, wastes and waste costs and environmental, health and safety costs, as well as increasing speed of production and improving post-casting sand removal. Using QFDs to Determine Influence Quality function deployment Quality function deployment or "QFD" is a flexible and comprehensive decision making technique used in product or service development, brand marketing, and product management. (QFD QFD Quality Function Deployment QFD Quantum Fluid Dynamics QFD Quality Functional Development QFD Quincy Fire Department (Massachusetts) ) charts can indicate the level of correlation correlation In statistics, the degree of association between two random variables. The correlation between the graphs of two data sets is the degree to which they resemble each other. of process requirements to end products. Level 1 (Fig. 1) depicts a metalcaster's requirements, which can be correlated cor·re·late v. cor·re·lat·ed, cor·re·lat·ing, cor·re·lates v.tr. 1. To put or bring into causal, complementary, parallel, or reciprocal relation. 2. with features referred to as critical to quality (CTQ CTQ Centre de Toxicologie du Québec CTQ Critical To Quality CTQ Cysteine Tryptophylquinone CTQ Confined to Quarters ) characteristics. These measurements are used to benchmark A performance test of hardware and/or software. There are various programs that very accurately test the raw power of a single machine, the interaction in a single client/server system (one server/multiple clients) and the transactions per second in a transaction processing system. , monitor and improve operational efficiency. The metalcaster may use these measurements to differentiate differentiate /dif·fer·en·ti·ate/ (dif?er-en´she-at) 1. to distinguish, on the basis of differences. 2. to develop specialized form, character, or function differing from that surrounding it or from the original. the "better" binder from the "good" binder. The QFD Level 2 (Fig. 2) correlates metalcaster CTQs with PUCB core and coremaking properties. Typically, varying levels of correlation range from low to high. If the assigned high correlation strength is real, then improvements to one or more of the identified PUCB core and coremaking properties should have a measurable contribution to meeting the metalcaster's CTQs. The QFD Level 2 also requires that test methods to probe the PUCB core and coremaking properties are assigned and capable. In many instances, established and standardized test A standardized test is a test administered and scored in a standard manner. The tests are designed in such a way that the "questions, conditions for administering, scoring procedures, and interpretations are consistent" [1] methods will provide adequate information. However, depending on the specific improvement needed, special test methods may have to be developed. Gage repeatability and reproducibility reproducibility Lab medicine The degree of agreement among repeated measurements of a particular parameter, presented in terms of a standard deviation or coefficient of variation of the results in a set of measurements determines the amount of variation present in the test as a proportion of the total measurement variation and can be used to assess the level of risk of acceptance of bad data or product or rejection Rejection Refusal by a bank to grant credit, usually because of the applicants financial history, or refusal to accept a security presented to complete a trade, usually because of a lack of proper endorsements or violation of rules of a firm. of good data or product. Using QFDs to Find Critical Materials Now that the measurement systems have been defined, the next step is to take the PUCB core and coremaking properties and correlate them with the materials used to make the core/mold (Fig. 3). The materials typically involved in PUCB coremaking are an aggregate such as sand and (sometimes) sand additives, a binder characterized char·ac·ter·ize tr.v. character·ized, character·iz·ing, character·iz·es 1. To describe the qualities or peculiarities of: characterized the warden as ruthless. 2. by its composition, a refractory refractory Material that is not deformed or damaged by high temperatures, used to make crucibles, incinerators, insulation, and furnaces, particularly metallurgical furnaces. coating and the suspension suspension, in vehicles suspension, in automobiles, system of springs used to suspend the frame, body, engine, and power train above the wheels. Its principal purpose is to lessen the jarring of the automobile that is caused by irregularities in the roads solvent solvent, constituent of a solution that acts as a dissolving agent. In solutions of solids or gases in a liquid, the liquid is the solvent. In all other solutions (i.e. from which it is applied, and an amine amine (əmēn`, ăm`ēn): see under amino group. amine Any of a class of nitrogen-containing organic compounds derived, either in principle or in practice, from ammonia (NH3). catalyst catalyst, substance that can cause a change in the rate of a chemical reaction without itself being consumed in the reaction; the changing of the reaction rate by use of a catalyst is called catalysis. . The PUCB binder system has two parts. Part 1 typically is comprised of a phenolic resin Noun 1. phenolic resin - a thermosetting resin phenolic, phenoplast synthetic resin - a resin having a polymeric structure; especially a resin in the raw state; used chiefly in plastics , solvents and performance additives. Part 2 contains isocyanate i·so·cy·a·nate n. Any of a family of nitrogenous chemicals that are used in industry and can cause respiratory disorders, especially asthma, if inhaled. , solvents and performance additives. The cured binder is best described as a phenolic-urethane polymer polymer (pŏl`əmər), chemical compound with high molecular weight consisting of a number of structural units linked together by covalent bonds (see chemical bond). which has a profound impact on a core's mechanical properties, resilience resilience (r  ·zilˑ·yens),n to atmospheric atmospheric /at·mos·pher·ic/ (at?mos-fer´ik) of or pertaining to the atmosphere. atmospheric of or pertaining to the atmosphere. conditions and performance when interacting with liquid metal. Depending on the type of phenolic resin and the isocyanate, a large spectrum of different phenolic-urethane polymers can be created. Solvent technology also is being viewed as critically important to the performance of the binder, both at coremaking and during subsequent stages of storage and at casting. Solvents make up 20-40% of the total binder composition and provide the basis for many property variations. Performance additives generally account for a small portion of the entire binder composition but result in significant effects. The variety of binder performance additives has grown over decades of PUCB process development. Many additive additive In foods, any of various chemical substances added to produce desirable effects. Additives include such substances as artificial or natural colourings and flavourings; stabilizers, emulsifiers, and thickeners; preservatives and humectants (moisture-retainers); and solutions are fixes for the trade-off properties created by older additives, As these are very cosily Co´si`ly adv. 1. See Cozily. Adv. 1. cosily - in a cozy manner; "nestled cozily by the fire" cozily cosily, cosiness cosy , this re-assessment of the technology either does not include the effects of additives or keeps their effects to a low and standardized standardized pertaining to data that have been submitted to standardization procedures. standardized morbidity rate see morbidity rate. standardized mortality rate see mortality rate. level within any comparison. The fact that a typical phenolic-urethane bonded core may consist of 99% sand and only 1% binder suggests that the sand source and quality play a major part in the properties of the core and possibly have an impact on the casting. The binder, however, is expected to compensate for any shortcomings A shortcoming is a character flaw. Shortcomings may also be:
In the fourth and final step of the present example, which aims at linking customer requirements to verifiable product (e.g. PUCB binder) and processing characteristics, the interactions of coremaking process controls with PUCB core and coremaking properties are considered (Fig. 4). In terms of coremaking process controls and variations, resin resin, any of a class of amorphous solids or semisolids. Resins are found in nature and are chiefly of vegetable origin. They are typically light yellow to dark brown in color; tasteless; odorless or faintly aromatic; translucent or transparent; brittle, fracturing addition (e.g. the binder level) is known to have an important effect, as does the geographical ge·o·graph·ic also ge·o·graph·i·cal adj. 1. Of or relating to geography. 2. Concerning the topography of a specific region. ge location of the core machine due to extreme variations in ambient Surrounding. For example, ambient temperature and humidity are atmospheric conditions that exist at the moment. See ambient lighting. conditions. Many of the other process controls were important issues that have a history of causing problems, so their control would be considered basic good metalcasting practice anywhere in the world. Mixed sand flowability is a more complicated property, not only related to the sand type and quality, but also to binder viscosity. By formulating the binders to one target viscosity, the impact of differences in sand flowability was kept to a minimum. Based on the above, five coremaking variables were determined to be of immediate interest and global impact: * sand; * binder solvents; * binder polymer; * resin addition; * location of manufacture and test. Testing Critical Characteristics Design of experiment techniques provide an approach to efficiently designing complex, large-scale large-scale adj. 1. Large in scope or extent. 2. Drawn or made large to show detail. large-scale Adjective 1. wide-ranging or extensive 2. experiments which will improve the understanding of the relationship between product and process parameters and the desired performance characteristics. For the performance comparison of different PUCB binders on different global sands, the following factors and levels were applied in the study: * Sand source--Four subangular Sub`an´gu`lar a. 1. Slightly angular. silica silica or silicon dioxide, chemical compound, SiO2. It is insoluble in water, slightly soluble in alkalies, and soluble in dilute hydrofluoric acid. Pure silica is colorless to white. sands with AFS A distributed file system for large, widely dispersed Unix and Windows networks from Transarc Corporation, now part of IBM. It is noted for its ease of administration and expandability and stems from Carnegie-Mellon's Andrew File System. AFS - Andrew File System GFN GFN Gone for Now GFN Gay Financial Network GFN Good For Nothing GFN Glass Filled Nylon GFN Group-Forming Network GFN Grand Forks, North Dakota (border patrol sector) GFN Goodbye for Now GFN Global Futures Network 50. * Binder solvent package--Aromatic hydrocarbon hydrocarbon (hī'drōkär`bən), any organic compound composed solely of the elements hydrogen and carbon. The hydrocarbons differ both in the total number of carbon and hydrogen atoms in their molecules and in the proportion of hydrogen solvents and ester solvents (S1 and S2). * Phenolic-urethane polymer--Results from combining phenolic resin with isocyanate (B1 and B2). * Resin addition--Two levels: 1% and 1.5%, measured as weight percent of binder based on sand, Part 1 and Part 2 applied in a ratio of 1:1. * Location of test piece manufacture and test--three test laboratories in the U.S., Europe Europe (y  r`əp), 6th largest continent, c.4,000,000 sq mi (10,360,000 sq km) including adjacent islands (1992 est. pop. 512,000,000). and Asia. The coremaking and casting
tests employed to comparatively evaluate the performance of the binders
were identified in Fig. 2:
* Coremaking * Tensile tensile, adj having a degree of elasticity; having the ability to be extended or stretched. and transverse To cross from side to side. strength * Tensile strength tensile strength Ratio of the maximum load a material can support without fracture when being stretched to the original area of a cross section of the material. When stresses less than the tensile strength are removed, a material completely or partially returns to its at 24 hours * Three hour mixed sand bench life tensile strength * Amine consumption and curing efficiency * Release and resin wipe-off * Hot distortion distortion, in electronics, undesired change in an electric signal waveform as it passes from the input to the output of some system or device. In an audio system, distortion results in poor reproduction of recorded or transmitted sound. * Casting * Gray iron erosion erosion (ĭrō`zhən), general term for the processes by which the surface of the earth is constantly being worn away. The principal agents are gravity, running water, near-shore waves, ice (mostly glaciers), and wind. wedge casting * Gray iron penetration The successful unauthorized breach of a security perimeter. See penetration test. casting * Gray iron warpage Warp´age n. 1. The act of warping; also, a charge per ton made on shipping in some harbors. block casting * Aluminum shakeout Shakeout A situation in which many investors exit their positions, often at a loss, because of uncertainty or recent bad news circulating around a particular security or industry. Notes: During the dotcom boom and bust, numerous shakeouts occurred. casting The casting surface finish was judged from both veining vein·ing n. Distribution or arrangement of veins or veinlike markings. and penetration castings. Veining, penetration, erosion and surface finish were rated visually using a scale of one to five, with one as the best and five as the worst. Warpage was measured as deflection deflection /de·flec·tion/ (de-flek´shun) deviation or movement from a straight line or given course, such as from the baseline in electrocardiography. de·flec·tion n. 1. of the core cavity cavity /cav·i·ty/ (kav´i-te) 1. a hollow place or space, or a potential space, within the body or one of its organs. 2. in dentistry, the lesion produced by caries. in the resulting casting. The raw data gained from the experiments were analyzed an·a·lyze tr.v. an·a·lyzed, an·a·lyz·ing, an·a·lyz·es 1. To examine methodically by separating into parts and studying their interrelations. 2. Chemistry To make a chemical analysis of. 3. statistically using analysis of variation techniques. A design factor with a large difference in contribution to the total variation from one level to another indicates that the factor is a significant contributor to the performance characteristic in question. Studying the Impact Binder level has a profound impact on core strength, both immediately and after 24 hours. The higher binder level results in higher strength. No effect of binder type on immediate strength was observed ob·serve v. ob·served, ob·serv·ing, ob·serves v.tr. 1. To be or become aware of, especially through careful and directed attention; notice. 2. . Little variation was noticed as a result of different sands. The greatest level of variation stemmed stemmed adj. 1. Having the stems removed. 2. Provided with a stem or a specific type of stem. Often used in combination: stemmed goblets; long-stemmed roses. from the test location (i.e. the lab). Both the effect of the binder level and test lab location were similar in the 24-hour strength evaluation. However, the binder did reveal trends resulting from both polymer and solvent composition. Compared to in, mediate MEDIATE, POWERS. Those incident to primary powers, given by a principal to his agent. For example, the general authority given to collect, receive and pay debts due by or to the principal is a primary power. strength development, the variability of the sand impact appears to increase over 24 hours, without assignable cause at the present time. In looking at warpage and erosion test results, it is interesting to note that while the effects of sand choice and resin addition were similar in both sets of tests, the choice of phenolic-urethane polymer and solvent package had different effects. Higher binder level resulted in reduced warpage and improved erosion performance of the core. Analysis of Variation The objective of the variation calculations is to assign a proportion of contribution to the total measured variation by each factor. All factors had a significant effect on at least one and usually more coremaking properties. The binder level had the largest effect on the greatest number of properties, while the variation in sands had the smallest effect on many of the properties. The variation between test locations was consistent in most properties. The contribution to variation arising from the casting tests and evaluation of casting properties resulted in a very different picture. Some casting properties were mostly sand-specific, while others were affected by all factors. The contribution of binder technology and binder level was significant in properties such as erosion resistance and warpage, and the binder level clearly dominated dom·i·nate v. dom·i·nat·ed, dom·i·nat·ing, dom·i·nates v.tr. 1. To control, govern, or rule by superior authority or power: shakeout. Veining proved to be completely independent of PUCB binder choice and addition and largely dependent upon the sand. For More Information "Testing Keeps Pace with PUCB Binders," R. Showman, K. Schumacher Schumacher is an occupational surname (German, "shoemaker"), and may refer to: People Sport
The Six Sigma Not to be confused with Sigma 6. Six Sigma is a set of practices originally developed by Motorola to systematically improve processes by eliminating defects.[1] A defect is defined as nonconformity of a product or service to its specifications. method. Six Sigma is a statistical measure of variation and a business philosophy that signifies that an organization is committed to understanding its customers' requirements and providing products and services at a level of no more than 3.4 defects per million opportunities In process improvement efforts, defects per million opportunities or DPMO (or nonconformities per million opportunities (NPMO)) is a measure of process performance. It is defined as 1. Define--Identifies the opportunity, strategic drivers and scope of the project. 2. Measure--Focuses on customer requirements, performance targets and approach to data collection. 3. Analyze--Addresses the concepts, design criteria Noun 1. design criteria - criteria that designers should meet in designing some system or device; "the job specifications summarized the design criteria" criterion, standard - the ideal in terms of which something can be judged; "they live by the standards of their and product development to meet critical quality and performance targets. 4. Validate--Evaluates the successful design, as well as potential weak points, which may be susceptible susceptible /sus·cep·ti·ble/ (su-sep´ti-b'l) 1. readily affected or acted upon. 2. lacking immunity or resistance and thus at risk of infection. sus·cep·ti·ble adj. to failure and determines product/manufacturing capability. 5. Implement--Defines the full scale production, supply chain management and commercial aspects of the product placement with the target customer(s). 6. Control--Monitors and establishes long-term Long-term Three or more years. In the context of accounting, more than 1 year. long-term 1. Of or relating to a gain or loss in the value of a security that has been held over a specific length of time. Compare short-term. capability and manufacturability of the product. Mark Stancliffe is technology development manager, Jorg Kroker is global technology director and Xianping Wang (Wang Laboratories, Inc., Lowell, MA) A computer services and network integration company. Wang was one of the major early contributors to the computing industry from its founder's invention that made core memory possible, to leadership in desktop calculators and word processors. is senior staff chemist (jargon) chemist - (Cambridge) Someone who wastes computer time on number crunching when you'd far rather the computer were working out anagrams of your name or printing Snoopy calendars or running life patterns. May or may not refer to someone who actually studies chemistry. for Ashland Ashland (ăsh`lənd). 1 Industrial city (1990 pop. 23,622), Boyd co., E Ky., on terraces along the Ohio River near the influx of the Big Sandy; settled 1786, inc. 1854. Casting Solutions. Stancliffe is based in Kidderminster Kidderminster, city (1991 pop. 50,385), Worcestershire, W central England. The city had a prosperous cloth trade from the 14th to 18th cent. Kidderminster carpets have been produced since 1735. Associated industries include spinning, dyeing, and metal forging. , England England, the largest and most populous portion of the United Kingdom of Great Britain and Northern Ireland (1991 pop. 46,382,050), 50,334 sq mi (130,365 sq km). It is bounded by Wales and the Irish Sea on the west and Scotland on the north. , and Kroker and Wang are based in Dublin, Ohio Dublin is a city in Delaware, Franklin, and Union counties in the U.S. state of Ohio. The population was 31,392 at the 2000 census. In 2006, the population was estimated to be 36,565[1], and Dublin continues to be one of the fastest-growing suburbs of Columbus. .
Fig. 1. QFD Level 1 depicts how metalcaster requirements
or needs can be correlated with features referred
to as critical to quality (CTQ) characteristics.
Customer CTQs/Measurements
Casting
scrap/
inspection Core
Importance cost strength/
to Customers, and time quality
1, 3 or 5
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
Customer Requirements 1 2
1 Reduce casting finishing 5 9 9
costs
2 Reduce the raw material 5
cost of cores
3 Reduce casting defects 5 9 3
4 Increase speed of core 5 1
production
5 Reduce wastage and waste 3 9 9
costs
6 Reduce core machine & 5 3
tooling downtime
7 Reduce EH&S Impact 3 1
8 Increase rate and 3
completeness of sand
removal, post cast
9
10
Technical Priorities
Relative Importance 117 110
Importance, % 14.6 13.8
Rank 1 2
Measurement units $ psi
Customer CTQs/Measurements
Core
Finishing Coating production
costs & time costs rate
Correlation: 9 = High, 3 = Medium,
1 = Low, Blank = No
Customer Requirements 3 4 5
1 Reduce casting finishing 9
costs
2 Reduce the raw material 9
cost of cores
3 Reduce casting defects 9
4 Increase speed of core 9 9
production
5 Reduce wastage and waste 3 1 1
costs
6 Reduce core machine & 9
tooling downtime
7 Reduce EH&S Impact 3 1
8 Increase rate and 1
completeness of sand
removal, post cast
9
10
Technical Priorities
Relative Importance 108 99 93
Importance, % 13.5 12.4 11.6
Rank 3 4 5
Measurement units $ $ /hr
Customer CTQs/Measurements
Core scrap
and waste Sand/sand
mixed sand Binder & additive
costs amine costs costs
Correlation: 9 = High, 3 = Medium,
1 = Low, Blank = No
Customer Requirements 6 7 8
1 Reduce casting finishing 1
costs
2 Reduce the raw material 3 9 9
cost of cores
3 Reduce casting defects 1 1
4 Increase speed of core 3
production
5 Reduce wastage and waste 9
costs
6 Reduce core machine & 3 1
tooling downtime
7 Reduce EH&S Impact 1
8 Increase rate and 3
completeness of sand
removal, post cast
9
10
Technical Priorities
Relative Importance 85 59 50
Importance, % 10.6 7.4 6.3
Rank 6 7 8
Measurement units %/$ $ $
Customer CTQs/Measurements
Injuries,
complains and
claims etc Decore time
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
Customer Requirements 9 10 Score
1 Reduce casting finishing 3 155
costs
2 Reduce the raw material 1 155
cost of cores
3 Reduce casting defects 115
4 Increase speed of core 110
production
5 Reduce wastage and waste 96
costs
6 Reduce core machine & 1 85
tooling downtime
7 Reduce EH&S Impact 9 45
8 Increase rate and 9 39
completeness of sand
removal, post cast
9
10
Technical Priorities
Relative Importance 47 32 800.0
Importance, % 5.9 4.0 100.0
Rank 9 10
Measurement units $ secs Totals
Fig. 2. QFD Level 2 correlates metalcaster CTQs
with PUCB core and coremaking properties.
Importance to
Customer CTQs/ Customers, 1,
Measurements 3 or 5
[down arrow] 1 Finishing costs & time 5
[down arrow] 2 Casting scrap / 5
inspection costs and
time
[up arrow] 3 Core strengths quality 5
[up arrow] 4 Core production rate 5
[down arrow] 5 Core scrap and waste 3
mixed sand costs
[down arrow] 6 Coating costs 5
[down arrow] 7 Binder & amine costs 5
[down arrow] 8 Decore time 3
[down arrow] 9 Injuries, complaints 3
and claims etc
[down arrow] 10 Sand / sand additive 5
costs
Technical Priorities
Relative Importance
Importance, %
Rank
Measurement units
Test Methods
[up arrow] [up arrow]
PUCB Core & Core Making
Product Properties
Casting Mixed
Customer CTQs/ erosion sand
Measurements resistance benchlife
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
1 2
[down arrow] 1 Finishing costs & time 9 9
[down arrow] 2 Casting scrap / 9 3
inspection costs and
time
[up arrow] 3 Core strengths quality 9 9
[up arrow] 4 Core production rate 1
[down arrow] 5 Core scrap and waste 1 9
mixed sand costs
[down arrow] 6 Coating costs 3 1
[down arrow] 7 Binder & amine costs
[down arrow] 8 Decore time
[down arrow] 9 Injuries, complaints 1 1
and claims etc
[down arrow] 10 Sand / sand additive
costs
Technical Priorities
Relative Importance 156 145
Importance, % 14.3 13.3
Rank 1 2
Measurement units %
Test Methods Erosion Wedge Drop in
Casting tensile with
3hrs old
mixed sand
[up arrow] [up arrow]
PUCB Core & Core Making
Product Properties
Core Casting
Customer CTQs/ storage surface
Measurements humidity finish
resistance
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
3 4
[down arrow] 1 Finishing costs & time 9 9
[down arrow] 2 Casting scrap / 3 9
inspection costs and
time
[up arrow] 3 Core strengths quality 9 3
[up arrow] 4 Core production rate 1
[down arrow] 5 Core scrap and waste 9 1
mixed sand costs
[down arrow] 6 Coating costs 1 3
[down arrow] 7 Binder & amine costs
[down arrow] 8 Decore time
[down arrow] 9 Injuries, complaints 1 1
and claims etc
[down arrow] 10 Sand / sand additive
costs
Technical Priorities
Relative Importance 145 126
Importance, % 13.3 11.5
Rank 2 4
Measurement units %
Test Methods Tensile Surface
stored 24hrs finish
@ 90%RH casting
[down arrow] [up arrow]
PUCB Core & Core Making
Product Properties
Core Core strength
Customer CTQs/ sticking
Measurements and tooling
resin
wipe-off
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
5 6
[down arrow] 1 Finishing costs & time 3 3
[down arrow] 2 Casting scrap / 3 3
inspection costs and
time
[up arrow] 3 Core strengths quality 3 9
[up arrow] 4 Core production rate 9 3
[down arrow] 5 Core scrap and waste 9 3
mixed sand costs
[down arrow] 6 Coating costs 1 1
[down arrow] 7 Binder & amine costs
[down arrow] 8 Decore time
[down arrow] 9 Injuries, complaints 1
and claims etc
[down arrow] 10 Sand / sand additive 1
costs
Technical Priorities
Relative Importance 125 109
Importance, % 11.4 10.0
Rank 5 6
Measurement units psi/gm psi
Test Methods Release and Tensile &
resin Transverse
wipe-off
test
[down arrow] [down arrow]
PUCB Core & Core Making
Product Properties
Amine
Casting consumption/
Customer CTQs/ veiring/ core curing
Measurements penetration times
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
7 8
[down arrow] 1 Finishing costs & time 9
[down arrow] 2 Casting scrap / 9 1
inspection costs and
time
[up arrow] 3 Core strengths quality 3
[up arrow] 4 Core production rate 9
[down arrow] 5 Core scrap and waste 3
mixed sand costs
[down arrow] 6 Coating costs
[down arrow] 7 Binder & amine costs 3
[down arrow] 8 Decore time
[down arrow] 9 Injuries, complaints 1 1
and claims etc
[down arrow] 10 Sand / sand additive
costs
Technical Priorities
Relative Importance 93 92
Importance, % 8.5 8.4
Rank 7 8
Measurement units %/sec
Test Methods Penetration Amine
casting consumption
& curing
efficiency
test
[down arrow] [down arrow]
PUCB Core & Core Making
Product Properties
Customer CTQs/ Casting Core
Measurements warpage shake-out
time posts
casting
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
9 10
[down arrow] 1 Finishing costs & time
[down arrow] 2 Casting scrap / 9
inspection costs and
time
[up arrow] 3 Core strengths quality 3
[up arrow] 4 Core production rate
[down arrow] 5 Core scrap and waste
mixed sand costs
[down arrow] 6 Coating costs
[down arrow] 7 Binder & amine costs 3
[down arrow] 8 Decore time 9
[down arrow] 9 Injuries, complaints
and claims etc
[down arrow] 10 Sand / sand additive
costs
Technical Priorities
Relative Importance 60 42
Importance, % 5.5 3.8
Rank 9 10
Measurement units in %
Test Methods Warage block Shake-out
casting casting
Customer CTQs/
Measurements Score
[down arrow] 1 Finishing costs & time 255
[down arrow] 2 Casting scrap / 245
inspection costs and
time
[up arrow] 3 Core strengths quality 240
[up arrow] 4 Core production rate 115
[down arrow] 5 Core scrap and waste 105
mixed sand costs
[down arrow] 6 Coating costs 50
[down arrow] 7 Binder & amine costs 30
[down arrow] 8 Decore time 27
[down arrow] 9 Injuries, complaints 21
and claims etc
[down arrow] 10 Sand / sand additive 5
costs
Technical Priorities
Relative Importance 1093.0
Importance, % 100.0
Rank
Measurement units Totals
Test Methods
Fig. 3. QFD Level 3 shows the relationship between
PUCB core and coremaking properties and the
materials used to make the core/mold.
Importance to
PUCB Core & Core Customers, 1,
Making Product Propert 3 or 5
[up arrow] 1 Core strength 5
[up arrow] 2 Casting surface 5
finish
[up arrow] 3 Mixed sand benchlife 3
[down arrow] 4 Core sticking and 5
tooling resin
wipe-off
[up arrow] 5 Casting erosion 5
resistance
[up arrow] 6 Core storage humidity 3
resistance
[down arrow] 7 Casting seining / 5
penetration
[down arrow] 8 Amine consumption / 3
core curing times
[down arrow] 9 Core shakeout timex 3
core curing times
[down arrow] 10 Casting warp age 5
Technical Priorities
Relative Importance
Importance, %
Rank
Measurement units
Core Raw Materials
Sand source/ Solvents
quality
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
PUCB Core & Core
Making Product Propert 1 2
[up arrow] 1 Core strength 9 9
[up arrow] 2 Casting surface 9 3
finish
[up arrow] 3 Mixed sand benchlife 9 9
[down arrow] 4 Core sticking and 3 9
tooling resin
wipe-off
[up arrow] 5 Casting erosion 3 1
resistance
[up arrow] 6 Core storage humidity 3 9
resistance
[down arrow] 7 Casting seining / 9
penetration
[down arrow] 8 Amine consumption / 1 9
core curing times
[down arrow] 9 Core shakeout timex 3 3
core curing times
[down arrow] 10 Casting warp age 3 1
Technical Priorities
Relative Importance 228 205
Importance, % 21.2 19.1
Rank 1 2
Measurement units
Core Raw Materials
Sand PU polymer
additives
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
PUCB Core & Core
Making Product Propert 3 4
[up arrow] 1 Core strength 9 9
[up arrow] 2 Casting surface 9 3
finish
[up arrow] 3 Mixed sand benchlife 9 9
[down arrow] 4 Core sticking and 3 3
tooling resin
wipe-off
[up arrow] 5 Casting erosion 3 3
resistance
[up arrow] 6 Core storage humidity 1 1
resistance
[down arrow] 7 Casting seining / 9
penetration
[down arrow] 8 Amine consumption / 1 3
core curing times
[down arrow] 9 Core shakeout timex 1 3
core curing times
[down arrow] 10 Casting warp age 3
Technical Priorities
Relative Importance 201 153
Importance, % 18.7 14.2
Rank 3 4
Measurement units
Core Raw Materials
Resin Coating
additives refractory
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
PUCB Core & Core
Making Product Propert 5 6
[up arrow] 1 Core strength 3
[up arrow] 2 Casting surface 1 9
finish
[up arrow] 3 Mixed sand benchlife 9
[down arrow] 4 Core sticking and 9
tooling resin
wipe-off
[up arrow] 5 Casting erosion 9
resistance
[up arrow] 6 Core storage humidity 9
resistance
[down arrow] 7 Casting seining / 1
penetration
[down arrow] 8 Amine consumption / 3
core curing times
[down arrow] 9 Core shakeout timex 3
core curing times
[down arrow] 10 Casting warp age
Technical Priorities
Relative Importance 137 95
Importance, % 12.7 8.8
Rank 5 6
Measurement units
Core Raw Materials
Coating Amine type
solvent
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
PUCB Core & Core
Making Product Propert 7 8
[up arrow] 1 Core strength 1 1
[up arrow] 2 Casting surface
finish
[up arrow] 3 Mixed sand benchlife 3
[down arrow] 4 Core sticking and
tooling resin
wipe-off
[up arrow] 5 Casting erosion 1
resistance
[up arrow] 6 Core storage humidity 9 1
resistance
[down arrow] 7 Casting seining /
penetration
[down arrow] 8 Amine consumption / 1
core curing times
[down arrow] 9 Core shakeout timex
core curing times
[down arrow] 10 Casting warp age
Technical Priorities
Relative Importance 37 20
Importance, % 3.4 1.9
Rank 7 8
Measurement units
Core Raw Materials
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
PUCB Core & Core
Making Product Propert 9 10
[up arrow] 1 Core strength
[up arrow] 2 Casting surface
finish
[up arrow] 3 Mixed sand benchlife
[down arrow] 4 Core sticking and
tooling resin
wipe-off
[up arrow] 5 Casting erosion
resistance
[up arrow] 6 Core storage humidity
resistance
[down arrow] 7 Casting seining /
penetration
[down arrow] 8 Amine consumption /
core curing times
[down arrow] 9 Core shakeout timex
core curing times
[down arrow] 10 Casting warp age
Technical Priorities
Relative Importance
Importance, %
Rank
Measurement units
PUCB Core & Core
Making Product Propert Score
[up arrow] 1 Core strength 205
[up arrow] 2 Casting surface 170
finish
[up arrow] 3 Mixed sand benchlife 144
[down arrow] 4 Core sticking and 135
tooling resin
wipe-off
[up arrow] 5 Casting erosion 100
resistance
[up arrow] 6 Core storage humidity 99
resistance
[down arrow] 7 Casting seining / 95
penetration
[down arrow] 8 Amine consumption / 54
core curing times
[down arrow] 9 Core shakeout timex 39
core curing times
[down arrow] 10 Casting warp age 35
Technical Priorities
Relative Importance 1076.0
Importance, % 100.0
Rank
Measurement units Totals
Fig. 4. QFD Level 4 considers the interactions of
coremaking process controls with PUCB core and
coremaking properties.
PUCB Core & Core Importance to
Making Product Customers, 1,
Properti 3 or 5
[up arrow] 1 Core strength 5
[down arrow] 2 Core sticking and 5
tooling resin wipe-off
[up arrow] 3 Mixed sand benchlife 3
[up arrow] 4 Casting surface finish 5
[up arrow] 5 Core storage humidity 3
resistance
[down arrow] 6 Amine consumption / 3
core curing times
[up arrow] 7 Casting erosion 5
resistance
[down arrow] 8 Core shake-out time 3
post casting
[down arrow] 9 Casting warpage 5
[down arrow] 10 Casting wining / 5
penetration
Technical Priorities
Relative Importance
Importance, %
Rank
Measurement units
[down arrow] [up arrow]
Core Making Process Controls
Resin Air
addition quality
(dryness)
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
PUCB Core & Core
Making Product
Properti 1 2
[up arrow] 1 Core strength 9 9
[down arrow] 2 Core sticking and 9 3
tooling resin wipe-off
[up arrow] 3 Mixed sand benchlife 1 9
[up arrow] 4 Casting surface finish 9 3
[up arrow] 5 Core storage humidity 3 9
resistance
[down arrow] 6 Amine consumption /
core curing times
[up arrow] 7 Casting erosion 3
resistance
[down arrow] 8 Core shake-out time 9
post casting
[down arrow] 9 Casting warpage
[down arrow] 10 Casting wining /
penetration
Technical Priorities
Relative Importance 189 129
Importance, % 24.0 16.3
Rank 1 2
Measurement units
Core Making Process Controls
Location Good tooling
(ambient design
temperature/
humidity)
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
PUCB Core & Core
Making Product
Properti 3 4
[up arrow] 1 Core strength 3 3
[down arrow] 2 Core sticking and 3 9
tooling resin wipe-off
[up arrow] 3 Mixed sand benchlife 9
[up arrow] 4 Casting surface finish 1 3
[up arrow] 5 Core storage humidity 9
resistance
[down arrow] 6 Amine consumption / 9
core curing times
[up arrow] 7 Casting erosion 3
resistance
[down arrow] 8 Core shake-out time
post casting
[down arrow] 9 Casting warpage
[down arrow] 10 Casting wining /
penetration
Technical Priorities
Relative Importance 104 102
Importance, % 13.2 12.9
Rank 3 4
Measurement units
[up arrow]
Core Making Process Controls
Mixed sand Good gas &
flowability purge
settings and
venting
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
PUCB Core & Core
Making Product
Properti 5 6
[up arrow] 1 Core strength 9 3
[down arrow] 2 Core sticking and 3
tooling resin wipe-off
[up arrow] 3 Mixed sand benchlife 3
[up arrow] 4 Casting surface finish 3
[up arrow] 5 Core storage humidity 3
resistance
[down arrow] 6 Amine consumption / 9
core curing times
[up arrow] 7 Casting erosion 1
resistance
[down arrow] 8 Core shake-out time
post casting
[down arrow] 9 Casting warpage
[down arrow] 10 Casting wining /
penetration
Technical Priorities
Relative Importance 89 51
Importance, % 11.3 6.5
Rank 5 6
Measurement units
[down arrow] [down arrow]
Core Making Process Controls
Blow pressure Sand
temperature
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
PUCB Core & Core
Making Product
Properti 7 8
[up arrow] 1 Core strength 1 3
[down arrow] 2 Core sticking and 9
tooling resin wipe-off
[up arrow] 3 Mixed sand benchlife 9
[up arrow] 4 Casting surface finish
[up arrow] 5 Core storage humidity
resistance
[down arrow] 6 Amine consumption /
core curing times
[up arrow] 7 Casting erosion
resistance
[down arrow] 8 Core shake-out time
post casting
[down arrow] 9 Casting warpage
[down arrow] 10 Casting wining /
penetration
Technical Priorities
Relative Importance 50 42
Importance, % 6.3 5.3
Rank 7 8
Measurement units
[down arrow]
Core Making Process Controls
Operator
training/
experience
Correlation: 9 = High,
3 = Medium, 1 = Low,
Blank = No
PUCB Core & Core
Making Product
Properti 9 10
[up arrow] 1 Core strength 3
[down arrow] 2 Core sticking and
tooling resin wipe-off
[up arrow] 3 Mixed sand benchlife 3
[up arrow] 4 Casting surface finish
[up arrow] 5 Core storage humidity
resistance
[down arrow] 6 Amine consumption / 3
core curing times
[up arrow] 7 Casting erosion
resistance
[down arrow] 8 Core shake-out time
post casting
[down arrow] 9 Casting warpage
[down arrow] 10 Casting wining /
penetration
Technical Priorities
Relative Importance 33
Importance, % 4.2
Rank 9
Measurement units
PUCB Core & Core
Making Product
Properti Score
[up arrow] 1 Core strength 215
[down arrow] 2 Core sticking and 180
tooling resin wipe-off
[up arrow] 3 Mixed sand benchlife 102
[up arrow] 4 Casting surface finish 95
[up arrow] 5 Core storage humidity 72
resistance
[down arrow] 6 Amine consumption / 63
core curing times
[up arrow] 7 Casting erosion 35
resistance
[down arrow] 8 Core shake-out time 27
post casting
[down arrow] 9 Casting warpage
[down arrow] 10 Casting wining /
penetration
Technical Priorities
Relative Importance 789.0
Importance, % 100.0
Rank
Measurement units Totals
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