Abstract
Inefficiencies in the process chain result in bloated operational costs and ostensibly pass on to the customer. It is essential to streamline process costs and categorise them appropriately as either costs of conformance or cost of non-conformance. In this way, hidden costs due to inefficiencies in the system can be identified. A sustained continuous improvement programme to systematically eliminate waste can be employed to achieve lean manufacturing or “cleaner production”. A number of factors contribute to costs in a foundry from procurement of scrap to the delivery of a casting.