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Cleaner production strategies in small scale foundries

E Nand Gopal, Research Associate, Industrial Energy Efficiency Division, TERI

Ramesh D, Fellow, Industrial Energy Efficiency Division, TERI

Abstract

The Micro, Small and Medium enterprises (MSME) play a vital role in Indian

economy. Currently, the MSME industries contribute around 17% to the GDP and

provide employment to over 60 million people. Also, MSME industries account for

country’s 95% of total industrial activities and 40% of total exports. A single MSME

unit may consume less amount of energy but when considered as a cluster, they are

highly energy intensive. There are more than 4500 foundries in India and 80% of

them are small scale industries. This paper describes the role and need of cleaner

production strategies in small scale foundries. Energy efficiency plays a significant

role in attaining cleaner production. This paper focuses on achieving cleaner

production by means of energy efficiency in foundry equipment (quantitative

approach) and by achieving total quality control through Kaizen activities

(qualitative approach). The quantitative approach deals with various energy

conservation measures, which arise as result of carrying out detailed energy audit.

The qualitative approach focuses on 5S activities and small group activities to achieve

total quality control. All results presented in paper are from research carried out in 70

small scale foundries in Kolhapur (Maharashtra, India) industrial cluster. Kolhapur

cluster has approximately 300 foundries.

Key word

MSME, Foundries, Specific energy consumption, Energy efficiency, Resource

efficiency, Kaizen activity

1. Introduction

Small Scale Enterprises (SME) are significant for economic growth and dynamism in all

economies. For developing and transition economies in particular, SME holds key for wider

economic development and poverty alleviation. Definition of SME varies quite widely from

country to country and sometimes, even within the same country [1]. In India the micro,

small and medium enterprises are classified into two classes: manufacturing enterprise and

service enterprise. The manufacturing enterprises are defined in terms of investment in

plant and machinery [2]:

Micro enterprise : < INR 25 lakh

Small enterprise : INR 25 lakh to INR 5 crore

Medium enterprise : INR 5 crore to INR 10 crore

The MSME contributed 17% to the nation’s GDP in FY’11 and employed 60 million people,

second next to agriculture. Further, MSMEs account for 40% of total exports [3]. MSMEs

account for 95% of total industrial activities in India [4].

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The Indian foundry industry has annual production of over 9.9 million tonnes of casting (see

figure 1) and accounts for 8-9% of total casting production of the world [6]. There are more

than 4,500 foundry units in India, 80% of these are MSMEs [5]. MSME foundries are backbone

of Indian manufacturing sector. MSME foundries are located in various clusters in India.

Kolhapur is one such cluster, located in Maharashtra. Kolhapur foundry cluster has

approximately 300 foundries. A single foundry MSME unit may consume less amount of

energy but when considered as a cluster, they are highly energy intensive. For instance, the

total energy consumption of Kolhapur foundry cluster is 178,777 toe per year, whereas

energy consumption per unit is around 510 toe [5]. Energy bill accounts to 15-20% of total

production cost in small scale foundries. The specific energy consumption, i.e. energy

consumed to manufacture one tonne of good casting varies considerably from unit to unit.

Many energy studies have been conducted in the foundry sector to improve its specific

energy consumption and there still remains a vast scope of improvement. The need for

today’s foundry industries is cleaner production strategies for reducing energy consumption

and thereby improving resource efficiency.

Figure 1 Production of Casting in India

Source: http://www.foundryinfo-india.org/Production_of_castings.aspx

In this paper, the crucial role energy efficiency and Kaizen activities in achieving better

resource efficiency is explained. A structured discussion on various energy conservation

measures (ECM) is presented in the paper, which are a result of energy studies conducted in

MSME foundries in the Kolhapur cluster. The need for total quality control and its

troubleshooting by adopting Kaizen activities such as 5S, employee suggestion system and

small group activities are also discussed in following sections. The results presented in

paper are result of 12 months study conducted in 70 MSME foundries in Kolhapur cluster.

The paper concludes with recommendations/strategies to achieve cleaner production in

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small scale foundries. The study has focussed on sand moulding casting process as it is

currently adopted in around 90% of foundries in India. Major attention is given to ferrous

foundries.

2. Literature Review 2.1 An outline of process

The foundry industry is energy intensive and energy cost is 15-20% of total production cost.

Casting requires energy during different stages of production. In its simplest form the

processes are identified in five major stages as shown in figure 2.

Figure 2 Major stages in casting process

The major steps of process are mould sand & core preparation, charge preparation followed

by melting, pouring, knockout and finishing. Mould sand preparation is the first step in

foundry; fresh sand is mixed with bentonite and other additives and mixed in muller to

make green sand. Cores are forms that are placed into the mould to create the interior

contours of the casting. The prepared sand is filled in moulding box and then pneumatically

or hydraulically pressed to make the final mould. Raw material is segregated and readied

for charging into furnace where melting takes place. Once melted, the molten metal is

poured into the mould box by ladles and allowed to cool for definite pre-determined time.

After cooling, box is placed on a knock-out machine, which has a grated base, once switched

on the base vibrates thus making sand fall down and casting is taken for finishing followed

by quality check and then dispatched.

2.2 Energy consumption pattern

Foundry uses two main forms of energy: coke and electricity. Induction furnace is used for

melting, electricity accounts for 85-95% of total energy consumption. If a unit has heat

treatment, then diesel accounts for 15-25% of energy consumption. In cupola based foundry

coke, accounts for 85-95% of the total energy consumption by the unit. The energy

consumption pattern is helpful to identify energy utilization and wastage areas. A typical

foundry has energy consumption in melting, mould and core preparation, sand

preparation, compressed air system, lighting and miscellaneous areas. A distribution of

energy consumption in MSME foundry is given in figure 3.

Sand and Core

Preparation Moulding

Charge Preparation

Melting

Pouring Knock-out Finishing

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Figure 3 Distribution of energy consumption in typical foundry

Source: M Arasu, L Rogers Jeffery “Energy consumption studies in cast iron foundries”

2.3 Specific energy consumption

The specific energy consumption (SEC) of melting is the energy consumed for melting one

tonne of liquid metal. SEC of entire unit is energy consumed for producing one tonne of

good saleable casting. Table 1 shows average SEC of melting for induction furnace and

cupola based foundry [7]. The SEC of melting depends on several factors, such as operating

practice, raw material quality, refractory condition, capacity utilization. Hence the SEC

given in table 1 is average indicator.

Table 1 Specific Energy consumption

Sr. No. Description Energy Consumption

1 SEC of melting by induction furnace 620 kWh/tonne

2 SEC of melting by cupola (using coke) 135 kg/tonne

Source: M Arasu, L Rogers Jeffery “Energy consumption studies in cast iron foundries”

2.4 Resource efficiency

The resource efficiency in foundries comprises of the following: technology & procedure,

product & its type and organisation & management. There are several indicators of resource

efficiency in foundry, major parameters are:

Process yield,

Energy consumption and

Labour productivity

Process yield of a foundry is result of four sub-indicators: melting loss, pig and spillage,

runner & riser and rejects. Energy consumption of the foundry is result of two sub-

indicators: energy consumption for melting and for rest of process. Labour productivity is

represented in man-hour per tonne of good casting.

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2.5 Learning’s from other nation’s foundries

A number of studies in past have made an attempt to improve performance of foundry by

conducting energy audits and using best operating practices. Buying right scrap (free from

rust, sand, dirt and oil) can result in lower slag content, thus reducing melting losses, and

use of higher efficiency motors in mould making can save 2-5% energy in moulding process

[10]. One of the British Cast Iron Research Association, BCIRA’s reports enlighten about

importance of metal balancing and proper gating design for improving net yield of foundry.

It also explains in detail the best operating practices for a coreless induction furnace [11].

International Finance Corporation, IFC’s study reveals the importance of resource efficiency

and elaborates on various parameters of resource efficiency [8]. Resource efficiency

parameters play a vital role in performance of any foundry and by taking proper steps these

performance parameters can be improved in Indian foundries. Canadian Industry Program

for energy Conservation, CIPEC’s report on energy efficient opportunities in Canadian

foundries emphasises on significance of having an energy management plan, and

recommends following PDCA (Plan, Do, Check and Act) on all energy saving options and

proposes a methodology to follow PDCA [12]. Foundrybench’s report portrays energy

efficient management system, increasing process integration and effective process control as

techniques for achieving energy efficiency [15].

2.6 Studies on Indian foundries

A study carried out by National Productivity Council (NPC) [9] shows energy saving

potential in induction melting furnace and in its auxiliaries. The report states the radiation

heat losses from top opening of furnace is about 3% of furnace input energy and about 80%

of this waste heat can stopped by providing lid cover to furnace. The NPC study also shows

detection of air leakages in compressed air system, proper maintenance of pumping system

and effective lighting control can lead to energy saving [9]. In Indian foundries the use of lid

cover in not common and there are a lot of air leakages in the compressed air system; these

are potential energy saving areas. A study by CII on foundries in Batala, Ludhiana and

Jalandhar elaborates on the following energy conservation measures [13]:

Maintaining good power factor

Replacement of old lighting fixtures by new efficient ones

Replacement of re-winded motors and providing lid cover for furnace.

Many MSME owners lack the edge over their contemporaries in terms of exposure and

knowledge on energy efficient appliances. The opportunity is to educate the owners on

energy efficiency. TERI-SDC has done research in cupola based foundries in many clusters

in past one and half decade, results from the study are compiled and published as a report.

The report recommends replacing conventional cupolas by divided blast cupola. It also

explains various benefits of not only in energy (coke) saving but also reduced environmental

pollution [14]. BEE in partnership with the Institute for Industrial Productivity (IIP) initiated

an activity for the development of best practice guide for the foundry sector in India [16]. The

guide discusses:

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Choice of alternate technology available and

Describes the processes, materials and equipment necessary to realise the technology

choice

The foundry can achieve cleaner production by formulating and implementing strategies to

improve resource efficiency. The strategies can be quantitative and qualitative in nature. The

strategies would focus on improving process yield, energy consumption and labour

productivity, which would lead to improvement in resource efficiency. Quantitative

strategies include conducting detailed energy audit of casting process and process

equipment. Qualitative strategies include total quality control by implementing Kaizen

activities. The materials and methods followed in the study are elaborated in next section.

3. Material and Methods

First step in the methodology used for improvement of resource efficiency included

conducting preliminary survey in sample of units for data collection. Based on the data

collected a methodology was developed for conducting detailed energy audit and for

implementation of Kaizen activity. Methods used for preliminary survey, detailed energy

audit and Kaizen activities are explained below.

3.1 Preliminary survey

Preliminary survey is conducted for a sample set of units to collect data. A typical

questionnaire is prepared to make task of data collection easier. The data on different

process equipment and utilities used by the unit is collected. The details of consumption of

different energy forms are collected along with production and man power details. The

particulars of loss of metal at various stages of casting process are also collected.

Observations and deductions are made by reviewing the data collected.

3.2 Detailed energy audit [17]

The energy audit is one of the first jobs to be performed in the achievement of an effective

energy cost control program. The step by step process of energy audit is given in figure 4.

Figure 4 Steps of detailed energy audit

Implementation of selected ECOs

Techno-economic evaluation of ECOs

Post audit analysis and identification of ECOs

Measurement and trails

Data Collection

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An energy audit consists of detailed examination of energy consumption pattern of unit,

types of energy sources used and their costs. The data collected during the preliminary

survey is analysed to depict a picture of how the foundry uses and/or wastes energy. The

operating parameters of equipment under operation are measured using sophisticated

portable instruments. Comparison is drawn between rated parameters of all equipment and

measured parameters. Based on this energy conservation opportunities (ECO) are identified.

Cost effectiveness and other benefits of the ECOs are compared, and discussions are made

on practical feasibility and overall impact of ECOs on resource efficiency. Finally, a

thorough plan is created where certain ECOs are selected for implementation, and the actual

process of saving energy and saving money begins. The instruments commonly needed for

energy audits and their purpose are listed in table 2.

Table 2 Instruments used in energy audit of foundry

Instrument Application Measurement

Power analyser Electrical Parameters

Harmonics analysis

Induction furnace, Air

Compressor, Pumps, Motors,

Lighting, Other electrical

equipment

Ultrasonic flow meter Water Velocity ,Volume Pumping system

Flue gas analyser Flue gas O2 ,CO,CO2 and

Temperature

Heat treatment furnace, Diesel

fired melting furnace, Cupola

Hygrometer Ambient Temperature & RH

Digital temperature indicator Temperature

Thermal imager Surface temperature and image Core shooter, Furnace

temperature, Heat treatment

Lux meter Lumen level Below lighting fixture

Infrared thermometer Surface temperature Walls of furnace and heat

treatment

Anemometer Air velocity Air compressor

Thermocouple High temperature Furnace

3.3 Kaizen activity

Kaizen means continuous improvement. The Kaizen activity originated in the best Japanese

management practices and is dedicated to the improvement of productivity, efficiency,

quality and, in general, of business excellence [18]. The Kaizen methods and techniques are

valuable tools to improve productivity. The 5S techniques are instrumental in increase of

efficiency and productivity while ensuring a pleasant atmosphere in the industry. 5S,

suggestion system and small group activities are most important parts of Kaizen. In

Japanese, 5S is the short form of five words which present the concept of good maintenance.

5S activities are the starting point for production activities. 5S stands for Sort (Seiri), Shine

(Seiton), Set in order (Seisou), Standardise (Seiketsu) and Sustain (Sitsuku). It is extremely

important to define the structure of the 5S teams in order to ensure the good development of

actions.

The steps followed in 5S are given below:

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Definition of 5S

5S implementation committee

Development of action plan

Advanced preparation

Clarification of objectives and effectiveness

Creation of 5S standards

Sort and shine

Set in order

Standardise and sustain

Company-wide implementation

The suggestion system brings out creativity and innovativeness in employee at production

site. The suggestions given by employee are evaluated and good suggestions are

implemented. Employee are given incentive if they give good suggestion, this creates

motivation among employees to come up with innovative and new suggestions. It aims to

enhance management of plant thus resulting in better labour productivity. Measures for

Implementing Suggestion System are:

Suggestion system

Submission of suggestions

Examination of suggestions

Release the examination results

Evaluation and bonus

Selection and implementation

In quality control (QC) there are always problems and the QC problem solving methods lies

in the way of thinking. This can be enhanced by forming small groups and conduction small

group activities every month. Small group activities are implemented by following the

below steps:

Selection of theme

Examining present state and setting objectives

Preparation of activity plan

Analysis of factor

Consideration of countermeasures and implementation

Confirm effects

Establishment of standardisation and management

Reflection and future issues

The above mentioned materials and methods are utilized to achieve better resource

efficiency in foundry. Preliminary survey provides data, which shows current level of

resource efficiency, hence giving idea how to improve it. Detailed energy audit and Kaizen

activities are tools used to improve process yield, energy consumption and labour

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productivity. The results of cleaner production strategies in small scale foundries are

discussed in the next section.

4. Results and discussion

The results and discussion presented are result of 12 month long study conducted in

Kolhapur MSME foundry cluster. Preliminary survey was conducted in 134 foundries,

detailed energy audit was carried out in 70 foundries and Kaizen activities are implemented

in 3 foundries. The results are discussed in two sub-sections:

4.1 Energy consumption reduction

Melting accounts for a major share in energy consumption in a foundry industry. The

important melting equipment are: induction furnace and cupola.

4.1.1 Induction furnace

Induction furnace used in MSME foundries come in different capacity (100kg to 5 tonne)

and power ratings (100kW to 2MW). Best SEC for melting cast iron in induction furnace

in India is around 565 kWh/tonne and average SEC is about 630 kWh/tonne, there is

massive gap between best and average. Whereas in European foundries best SEC is 558

kWh/tonne and average is 571 kWh/tonne [8]. These SECs are shown in figure 5. The

comparison shows there is a gap and steps can be taken to reduce the gap. Major loss of

energy in induction furnace occurs due to radiation heat loss from top opening. It

accounts to 3-4% of total input energy and can be saved by using a lid for the opening.

For example: During audit in one of the units following observation was made. Unit A

has a 750kg/750kW induction furnace without lid cover. The SEC of furnace was

measured to be 571kWh/tonne and heat loss from opening was 26kWh/tonne,

approximately 23kWh/tonne can be saved by using lid cover for induction furnace [20].

The water flow rate through the induction coil must be maintained at design level,

reduction in flow rate would result in heating of coil hence drop in life and performance

also increase in flow rate would result in excessive removal of heat and increase the

SEC. The operating practice and raw material quality holds key to best operation of

induction furnace. Raw material with oil/grease/dirt was seen to consume 2-3% more

energy consumption. Energy saving potential of 3-15% is possible in induction furnace.

Figure 5 SEC comparison of Induction Furnace in India and Europe for Cast Iron melting

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4.1.2 Cupola

Cupolas are of two type’s conventional single blast cupola and divided blast cupola

(DBC). DBC provides better performance than conventional cupola in terms of better

coke to metal ration, melting rate and molten metal quality. Average coke to metal ratio

for conventional cupola is around 1:8 to 1:10 whereas in DBC coke to metal ratio up to

1:15 can be easily attained. This shows energy saving potential of 10-40%. Minimum and

maximum saving potential in melting is 3% and 40% respectively. For example: During

audit in one of the units following observation was made. Unit B has 36 inch

conventional cupola the coke to metal ratio and melting rate were measured 1:5.1 and

4.17tonne/hour respectively. Replacing it by a DBC cupola of 36 inch would result in

minimum coke to metal ratio of 1:10 and melting rate of 6.5tonne/hour.

4.1.3 Compressed air system

Compressed air system is next major energy consuming part of casting process.

Compressed air is majorly used for pneumatic moulding, grinding and cleaning

purpose. Compressor accounts to 5-8% of total energy consumption in foundries.

Leakages of compressed air are noticed to be as ranging from 10-40%. Plugging all the

leakages will lead to energy saving of 5-35% in compressed air system. For example:

During audit in one of the units following observation was made. Unit C has installed

four air compressors with combined FAD capacity of 514cfm. Actual generated FAD

was measured 401cfm and leakages of 20% were identified. Fixing all leakages would

result in saving of 60cfm, which when translated to energy is 27.5% of total energy

consumption in compressed air system. Moreover compressor is found to be unloaded

for high time, thus showing scope of variable frequency drive (VFD) to improve loading

and reducing power consumption. VFD technology closely follows the air demand by

automatically adjusting the motor speed. This results in large energy savings of up to

35%. The life cycle cost of a compressor can be cut by an average of 22% [19]. The basic

control done by VFD is depicted in figure 6. Minimum and maximum saving potential

in compressed air system is 5% and 35% respectively.

Figure 6 Energy consumption by air compressor with and without VFD

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Source: Oil-injected Rotary Screw Compressors, Atlas Copco

4.1.4 Pumping system

Soft water is used to cool induction coils of furnace and raw is pumped through a heat

exchanger to cool soft water. Pumping system (pumps and cooling tower) accounts to 2-

4% of total energy consumption in foundry. In most cases, the pumps rating does not

match with design specification and motors of pumps are re-wound. By installing

correct design pumps of high efficiency minimum and maximum saving of 2% and 20%

respectively is achievable. For example in unit D the soft water pump was of 34% name

plate efficiency, the operating efficiency was calculated 27%, replacing it by higher

efficiency pump would result in saving of 14% energy.

4.1.5 Motors

Motors are used in many stages in foundry. In small scale foundries the motors capacity

is typically 5-10hp (except sand mixer, blender motor which is of higher rating). Most

motors have name plate full load efficiency less than 85%. In many cases turbine motor

of shot blast machine and sand mixer motors are found to be re-wound and of lower

efficiency. Replacing them by higher efficiency motors (greater than 88%) 2-10% saving

in motors can be achieved. For example: During audit in one of the units following

observation was made. Unit E the turbine motor of shot blast machine was of 70% rated

efficiency and operating efficiency was calculated 66%, replacing it with higher

efficiency motor would result in energy saving of 24%.

4.1.6 Lighting

Lighting is one of the most neglected areas in foundry. Conventionally foundries use

fluorescent tube light (FTL) of 40W with copper ballast (T12) for lighting in office and

stores. Sodium vapour lamp or mercury vapour lamp (MVL) are used in shop floor.

These are highly energy inefficient lighting fixtures. T12 FTL can be replaced by T5 FTL

and MVL can be replaced by metal halide without compromising on the lux level. The

luminous efficacy of different lighting fixtures is given in figure 7. Energy saving

potential in lighting varies between 5-40%. For example: During audit in one of the

units following observation was made. Unit F has 15 T12 FTL fixtures and 12 MVL

fixtures of 250W, which operates 12 hours per day. Replacing T12 by T5 and MVL by

metal halide would result in energy saving of 27%.

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Figure 7 Comparison of different lighting types

The energy consumption in foundry is explained in literature review, taking into

consideration all above mentioned ECOs, up to 13% of energy can be saved, and figure 8

portrays this saving. Sample energy audits were carried out in 70 MSME foundries in

Kolhapur cluster and minimum and maximum energy saving potential was 3% and 13%

respectively.

Figure 8 Distribution of energy consumption in a foundry and its saving potential

4.2 Process yield and labour productivity improvement

Process yield is an importance parameter of resource efficiency. The four components of

process yield are melting loss, pig & spillage, runner & riser and rejection. Average losses in

Indian and European foundry are shown in figure 9. Analysis of collected data shows scope

of improvement in process yield between 1-9%.

Labour productivity is also a significant parameter. The manpower input is measured in

terms of man-hours. Man power is of two types’ direct (labour) and indirect (management).

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The man power requirement in MSME foundries in India varies between 66.7 – 100 man-

hours per tonne of good casting. Unit to unit vast variation is seen in manpower

productivity.

Realisation of improvement in process yield and labour productivity can be achieved by

implementing Kaizen activities in foundry. 5S activity, employee suggestion system and

small group activities are the three key activities under Kaizen activity. A plan is made to

implement the activities and the plan is executed repeatedly to achieve continual

improvement. 5S activities are followed in raw material handling, pattern handling and

finishing process. The result of 5S can be directly seen in melting loss and rejection loss (both

decreases). For example 5S was implemented in Unit G in raw material handling, earlier the

melting loss was 6.5%, one and half year post implementation of 5S activity the melting loss

has come down to 3.5%.

Figure 9 Process yield comparison between Indian and European Foundry

Employee suggestion system is a simple way of involving all workers and making the task

interesting. A format is prepared for the suggestion system, all suggestions received are

evaluated and best suggestion is given reward. The feasible suggestions are implemented to

realise improvement in productivity and reduction in cost. For example suggestion system

was implemented in Unit G, total of 54 suggestions were received in first two months, 14 of

them were accepted and implementation resulted in improvement of quality. Indirect result

of suggestion system was positive involvement of all workers.

Small group activity is an innovative approach for problem solving. Problem is identified

via visualization of data; the solution to problem is attained by focussed group discussion.

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The Kaizen activities result in active involvement of entire workforces, hence improving

labour productivity. It also resulted in improvement of process yield.

5. Conclusion

Current practices in small scale foundries call for reforms in its production. This paper

identifies cleaner production strategies for small scale foundries, they are: conducting

energy audit in a timely fashion and implementing Kaizen activities.

Typical foundry has up to 13% energy saving potential

Melting losses can be brought down from existing 3.5 to below 2%

Pig and spillage can be brought down to below 2%

Rejection can be brought down to as low as 2%

For the same level of automation labour productivity can be brought down from

93.3 man-hours per tonne of good casting to 61.7 man-hours per tonne of good

casting.

Thus, it concludes that the energy intensive foundries must aim to enhance their energy

efficiency and implement Kaizen activities as it leads to multiple benefits and cleaner

production is ensured in the long run.

The study is still under progress for exploring more ways to improve resource efficiency.

The research work will focus on energy saving potential in induction furnace, cupola based

ferrous foundries and non-ferrous foundries and detailed analysis of results from units

where Kaizen activities have been implemented.

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