Application of TRIZ Methodology to Casting Process: A Case Study

Abstract

This paper discusses about how to solve problem arising from casting process by using the TRIZ Methodology. For this research, casting process was selected as the case study for applying the TRIZ methodology to solve the defects arise in the process; theory designed aims to solve the problem innovatively. Initial part of the report discussed about casting process and followed by the common type and cause of defects found in casting process. Further on, discussion in the report continue to discuss about the solution towards casting defects, it is done by using TRIZ methodology (Mini-ARIZ and 40 innovative principles). Principles selected will be applied in this report, it tends show how to solve manufacturing problem in casting and come out with an outstanding solution, which is cost effective and efficient from various aspect. As for result and outcome of experiment, TRIZ implementation brings a major impact towards the result of casting. During the case study, TRIZ application has successfully solved 4 main problems identified in the casting experiment; these defects are surface defects (pinholes), flash formation, rough surface and metallic projection by generating useful guidance and provides direction in future steps. The report also includes the result and verification of solution effectiveness, solution generated outcome has been verified and proven to be effective by experiment. In conclusion, TRIZ successfully solve the problem of flash formation, rough surface, metallic projection and reduce the formation of surface cavities.