What is a typical ppm performance level for casting suppliers?

R

richie p

#1
I would like to find out a typical external ppm performance level for casting suppliers.

I used to work within automotive and had a good feeling for acceptable levels of performance from all suppliers. I have just moved into aerospace where our current suppliers' performance is significantly worse than I am used to so I want to get some benchmarks to help me set an appropriate improvement target. Can anyone help?
 
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A

achorste

#2
Oooh.... Casting is an another animal entirely from typical forging & machining processes!

Are you finishing / machining raw / semi finished castings?

Typical reject rates for casting houses can be around 5% (That's 5% internal scrap and 5% rejection from customers due to latent defects). That's even in "world class" facilities.

The company I currently work for have a small casting facility 'bolted on' to the massive forging & machining operations. It's currently running at 17% scrap and about 3% reject from customer! :mg:
 
R

richie p

#3
Thanks for your feedback - the castings I am looking at are generally as cast. We then either send them on to a machinist for machining or machine them in house.
 

Kales Veggie

People: The Vital Few
#4
Oooh.... Casting is an another animal entirely from typical forging & machining processes!

Are you finishing / machining raw / semi finished castings?

Typical reject rates for casting houses can be around 5% (That's 5% internal scrap and 5% rejection from customers due to latent defects). That's even in "world class" facilities.

The company I currently work for have a small casting facility 'bolted on' to the massive forging & machining operations. It's currently running at 17% scrap and about 3% reject from customer! :mg:

These numbers quoted are in the range. For high volume gray iron casting (engine blocks), I have seen ranges 3%-5% internal and 3% additional after machining.
 
A

achorste

#5
It does depend on the casting types and what defects you're seeing though. Typically from a casting I would expect excellent dimensional results, but 'poor' results for inclusions, latent defects and visual defects (in comparison to forging / machining etc).
 
S

sundar_ksv

#6
The ppm level depends upon the profile, shape & size of the part made. But in my experience of auditing casting suppliers, I haven't ever come across rejection rate lesser than 8% (medium size casting industries handling SG Cast Iron).
Sometimes, the design of the part (stress concentration area) doesnt allow the casting manufacturer to design the gatings at the optimal areas, that have led to rejection to the tune of 15% to 20%.
I have come across instances wherein the action to reduce the rejection rate has resulted in reduced yield (lose - lose situation)
Generally, 5% is considered as a benchmark level.

Sundar
 
I

Ihab El tohamy

#7
Hi. Would you please, I need to know rejection rate for casting for part, like automotive brake disc
 
S

sky66666

#8
These numbers quoted are in the range. For high volume gray iron casting (engine blocks), I have seen ranges 3%-5% internal and 3% additional after machining.
Do you talked the target? I have others idea about it.
always , we can set up target by "SMART" principle,

the first,
the incoming acceptal level must comply with company quaitly targert.
such as, the DPPM of final quality in your company is 0 DPPM,
incoming acceptal level must be 0% too, becuase your compay can not achieve final quality object if incoming acceptal level is too low

the second,
the incoming acceptal level must comply with acceptal level last year.
why do that?
such as your acceptal level last year is 50%, and now you set up it on 3%.
it is impossible from 50% drop to 3%

Ps: I am poor of english ,and wish do not miss your topic.
by the way, pls friendly advise an other website about supplier management. thanks!
 
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