Table 2. Factor and Response Table for Steel Melting Factor (X)
Part Specific Range
Furnace operator (X4-1)
No. of heats on furnace (X4-2) Type of charge material (X4-3)
Time interval-power on-melt down (X4-4) Temperature at melt down (X4-5) MD (melt down) C (X4-6) MD Mn (X4-7) MD Si (X4-8) MD S (X4-9) MD P (X4-10) MD Ni (X4-11) MD Cr (X4-12) MD Mo (X4-13) MD Cu (X4-14)
Volume/time of O blow (X4-15) BB (before block) C (X4-16) Carbon drop (X4-17) BB Mn (X4-18) BB Si (X4-19) BB S (X4-20) BB P (X4-21) BB Ni (X4-22) BB Cr (X4-23) BB Mo (X4-24) BB Cu (X4-25)
Furnace block addition, FeSi (X4-26) Furnace block addition, FeMn (X4-27) Furnace block addition, SiMn (X4-28) Furnace alloy addition, Ni (X4-29) Furnace alloy addition, FeCr (X4-30) Furnace alloy addition, Mo (X4-31) PT (pre-tap) C (X4-32) PT Mn (X4-33) PT Si (X4-34) PT S (X4-35) PT P (X4-36) PT Ni (X4-37) PT Cr (X4-38) PT Mo (X4-39) PT Cu (X4-40)
Points of C blown per minute of O2 (X4-41) Points of Mn blown per minute of O2 (X4-42) Points of Si blown per minute of O2 (X4-43) Height of steel in ladle (X4-44) Al loss from tap to pour (X4-45) Mn loss from tap to pour (X4-46) Si loss from tap to pour (X4-47) Mn/S ratio (X4-48)
Factors and Responses Process knowledge is obtained
by knowing that Y is the function of X. In other words, metalcasters must determine factors or causes and their responses in each subprocess and activity in the foundry. In this case, responses are criteria relevant to
Method of Measurement
Log Data log
Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet Melt sheet
Units Nominal
Continuous/ Discrete C/D
Discrete
Number Continuous Nominal Hrs
Discrete Continuous
Deg. F Continuous % Continuous % Continuous % Continuous % Continuous % Continuous % Continuous % Continuous % Continuous % Continuous Continuous
Min
Lbs Lbs Lbs Lbs Lbs Lbs
% Continuous % Continuous % Continuous % Continuous % Continuous % Continuous % Continuous % Continuous % Continuous % Continuous Continuous Continuous Continuous Continuous Continuous Continuous
% Continuous % Continuous % Continuous % Continuous % Continuous % Continuous % Continuous % Continuous % Continuous
Melt/pour logs % Continuous Melt/pour logs % Continuous Melt/pour logs % Continuous Melt/pour logs % Continuous Melt/pour logs % Continuous Melt/pour logs % Continuous Melt/pour logs % Continuous Melt/pour logs % Continuous
internal or external customers. Major categories of responses are casting dimensions, casting defects, defects per million opportunities and quality costs. Te metalcaster’s job is to identify the factors in its processes that produce certain responses. Te process of making a casting
Response (Y)
Y2-2 (Inclusions) Y2-2 Y2-2 Y2-2 Y2-2
Y3-1 (Redlights) Y3-1 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1
Y2-12 (Cracks); Y2-7 (Hot tear) Y3-1 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1
Y2-11 (Blowholes, pinholes) Y2-11 Y2-11 Y2-11 Y2-11 Y2-11 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1 Y3-1
Y2-11 Y2-11 Y2-2 Y2-2
Y2-11 Y2-2 Y2-2 Y2-7
contains a series of activities that are performed to produce a defined result. Tese activities can be divided into levels. For example, Level 1 would be the casting process and Level 2 would be subprocesses such as management (marketing/sales, production control, finance), core processes (patternmak-
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